Industrial Stone Quarry Crushing Plant: Engineered for Maximum Tonnage and Minimum Downtime

1. PEMBUKAAN PAINPOINT DRIVEN

Managing a stone quarry’s primary crushing stage is a critical bottleneck. Suapan tidak konsisten, bahan kasar, and relentless operational demands directly impact your entire downstream process and profitability. Adakah anda menghadapi cabaran terkuantiti ini?

Kos Masa Henti Tidak Berjadual: A primary crusher failure can halt your entire operation, menelan belanja puluhan ribu sejam dalam pengeluaran yang hilang, buruh terbiar, and missed shipments.
High Wear Part Expenditure: The extreme abrasion of granite, basalt, or limestone leads to frequent and costly mantle, liner, and jaw replacements, cutting deeply into your margin per ton.
Inconsistent Throughput & Bentuk produk: Fluctuating feed size or poorly calibrated crushing chambers result in low yield of premium aggregate fractions and excessive recirculating load, straining secondary crushers.
Kos Tenaga yang Meningkat: Inefficient crushing action with poor nip angles or excessive stroke consumes disproportionate power without maximizing throughput.
Keselamatan & Kerumitan Penyelenggaraan: Panjang, manual setting adjustments and unsafe maintenance procedures for worn parts increase risk and extend repair windows.

Soalan utama untuk pengurus kilang adalah ini: How can you achieve predictable, highvolume primary reduction while controlling operational costs and protecting your downstream circuit?

2. GAMBARAN KESELURUHAN PRODUK

This product line encompasses stationary and semistationary primary crushing plants engineered for the initial reduction of blasted quarry rock. These plants are centered on highperformance jaw crushers or gyratory crushers designed for maximum intake size and durability.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Dump trucks or wheel loaders deposit shot rock into a rugged vibrating grizzly feeder.
2. PraSkrining & Bypass: The grizzly scalps out natural fines and subfeedsize material, directing it to a bypass conveyor to optimize crusher efficiency.
3. Pengurangan utama: Oversize material is conveyed into the crusher where immense compressive force breaks it down to a manageable size.
4. Primary Discharge: Crushed material is discharged onto a main product conveyor for transport to secondary processing or stockpiling.

Skop Permohonan & Batasan:
Skop: Sesuai untuk batu keras (granit, batu perangkap, basalt) and abrasive applications in hightonnage (>500 tph) quarrying operations. Configurations support feed sizes up to 60 inci.
Batasan: Not designed for very soft or lowabrasion materials like chalk or clay where alternative crusher types may be more economical. Requires significant capital investment and foundational civil works.

3. CIRI TERAS

Patented Cavity Design | Asas Teknikal: Kinematik dioptimumkan komputer & sudut nip | Faedah Operasi: Ensures continuous compression crushing with minimal slippage, reducing wear energy consumption | Kesan ROI: Data medan menunjukkan sehingga 12% lower cost per ton in abrasive stone applications.

Pelarasan Tetapan Hidraulik | Asas Teknikal: Integrated hydraulic cylinders for CSS control | Faedah Operasi: Allows operators to adjust product gradation in under 5 minutes without manual shims | Kesan ROI: Reduces downtime for product changeovers by over 90%, meningkatkan fleksibiliti tumbuhan.

Perhimpunan Galas Tugas Berat | Asas Teknikal: Forged alloy steel main shaft with oversized spherical roller bearings | Faedah Operasi: Supports extreme radial and axial loads from irregular feed | Kesan ROI: Memanjangkan hayat perkhidmatan galas dengan purata 30%, preventing catastrophic drivetrain failures.

Modular Liner Retention System | Asas Teknikal: Mechanically locked liner wedges | Faedah Operasi: Eliminates backing material use and enables faster, safer liner changes | Kesan ROI: Mengurangkan masa pertukaran pelapik lebih kurang 40%, lowering labor costs and exposure risk.

Pemacu Pintar & Protection System | Asas Teknikal: VFD compatibility with torquesensing automation | Faedah Operasi: Prevents stall conditions under tramp metal or overload scenarios | Kesan ROI: Protects motor and crusher from damage; documented case studies show a reduction in related electrical failures by over 60%.

Reinforced Fabricated Main Frame | Asas Teknikal: Analisis Unsur Terhingga (FEA) optimized steel plate construction with stressrelieving welds | Faedah Operasi: Menyediakan integriti struktur jangka panjang di bawah pemuatan kitaran | Kesan ROI: Mitigates frame fatigue cracking risk, safeguarding the longterm asset value of the plant.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | Our Quarry Crushing Plant Solution | Kelebihan Berdokumen |
| : | : | : | : |
| Adanya (Masa aktif) | 8892% in primary applications| >95% achievable availability| +47% jam yang lebih produktif setiap tahun |
| Manganese Wear Life (Granit Lelas) | ~600,000 tons per set| 850,000+ tons per set demonstrated| ~40% improvement in wear part utilization |
| Penggunaan Tenaga Khusus (kWj/tan)| Berbeza secara meluas; garis dasar = X kWj/t| Consistently measures at X0.15 kWh/t| Hingga 8% reduction in direct energy cost |
| Ketekalan Throughput (Tonnage Std Dev.)| High variance with feed fluctuation| Low variance via optimized feed control| Hingga 25% more consistent feed to secondary stage |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 500 ke 2,500 Ton metrik sejam (tph), bergantung pada model dan bahan suapan.
Crusher Type Options: Penghancur rahang tugas berat (900x1200mm to 1500x2000mm) or primary gyratory crushers (4265 inch feed opening).
Keperluan kuasa: Pemacu penghancur utama dari 200 kW sehingga 600 kw. Total plant installed power typically ranges from 400 kW kepada 1.2 MW.
Spesifikasi Bahan: Crusher liners manufactured from ASTM A128 manganese steel (Grade B3/B4). Main frame constructed from hightensile strength S355J2 steel plate.
Dimensi Fizikal (Typical Stationary Plant Footprint): Approximately 30m (L) x 15m (W) x 12m (H). Semistationary skidmounted options available with reduced footprint.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C. Piawaian sistem penindasan habuk; full enclosure options available.

6. SENARIO APLIKASI

Projek Pembesaran Kuari Granit

Cabaran: A southeastern US quarry needed to increase primary throughput by 50% without expanding their truck fleet or shot rock sizing. Their existing crusher created a bottleneck with excessive downtime for liner changes.
Penyelesaian: Implementation of a semistationary primary jaw crushing plant with hydraulic setting adjustment and modular liners was integrated upstream of the existing circuit.
Keputusan: Primary throughput increased by 58%. Liner change time reduced from 36 hours to under 20 jam. The project paid back through increased sales volume in under 22 bulan.

Basalt Aggregate Producer Facing High Wear Costs

Cabaran: A producer in volcanic rock was experiencing wear part costs that eroded 30% of their operating margin on base course material.
Penyelesaian: Replacement of an older impactstyle primary unit with a configured gyratory crushing plant featuring our patented cavity design.
Keputusan: Wear metal consumption decreased by 35% yearoveryear while maintaining the required product shape for asphalt chips. Penggunaan tenaga setiap tan menurun 9%.

7. PERTIMBANGAN KOMERSIL

Our quarry crushing plants are offered under three primary tiers:

1. Loji Tugas Standard ($2M $4M CAPEX): For consistent feed <1000mm, includes base crusher, penyuap, penghantar pelepasan, laluan pejalan kaki, tangga, and basic dust control.
2. Loji Tugas Berat ($4M $7M CAPEX): For severeduty applications with maximum feed size >1200mm includes reinforced structures automated lubrication system advanced condition monitoring sensors
3

Optional features include automated rock breaker systems metal detection tramp iron relief advanced PLC control integration remote monitoring telematics packages

Service packages range from basic commissioning extended warranty plans comprehensive multiyear maintenance agreements including planned wear part changes

Financing options are available including equipment leasing longterm rentaltoown structures project financing support tailored capital expenditure planning

Soalan Lazim

What level of foundation work is required?
These plants require significant engineered concrete foundations designed specific model load data we provide Civil drawings anchor bolt templates are supplied as part purchase agreement

Can this plant integrate with our existing PLC SCADA system?
Yes most models offer standard communication protocols Modbus TCP/IP OPC UA Integration support provided during commissioning ensure data exchange production rates motor amperes CSS settings

Apakah masa utama penghantaran biasa?
For standard configurations lead time ranges from months following design approval Custom designs may require additional engineering fabrication time Detailed schedule provided upon project initiation

Adakah anda menawarkan latihan pengendali?
Yes comprehensive onsite training included standard commissioning package covers safe operation routine maintenance procedures troubleshooting guides provided digital hard copy formats

How are wear parts priced supplied?
We offer transparent tiered pricing wear parts based projected annual consumption recommend maintaining strategic inventory critical items ensure uptime Local regional warehouse support available many territories

What happens if we encounter capacity issue after installation?
Our engineering team will perform audit identify constraint often related feed arrangement secondary screening recirculation load We provide actionable report potential upgrade paths optimize system performance

Adakah jaminan prestasi ditawarkan?
Yes we provide guaranteed minimum throughput capacity based agreed upon material characteristics feed size distribution written performance guarantee forms part commercial contract