1. PEMBUKAAN PAINPOINT DRIVEN

Are your limestone quarrying operations struggling with the balance between productivity and cost control? Cabaran biasa termasuk:

Penggerudian Tinggi & Blasting Costs: Inefficient fragmentation leads to excessive explosive use, keperluan pecah sekunder, and increased wear on primary crushers.
Masa Henti yang kerap untuk Penyelenggaraan: Unplanned equipment failures in harsh, abrasive limestone dust environments halt your entire processing chain.
Low Loader & Hauler Efficiency: Poorly sized or inconsistent feed material from the face reduces cycle times and increases fuel consumption per ton.
Rising Operational Overheads: Buruh, tenaga, and consumable costs are compressing your profit margins on every cubic meter extracted.
Persekitaran yang Tegas & Pematuhan Masyarakat: Menguruskan bunyi bising, getaran, and dust emissions is increasingly critical for maintaining your social license to operate.

How can you reduce your costperton without sacrificing reliable output? The answer lies in optimizing the initial extraction and primary reduction phases with purposeengineered equipment.

2. GAMBARAN KESELURUHAN PRODUK

The core of a costeffective limestone mining operation begins with a highperformance Penghancur rahang utama specifically configured for abrasive rock. This equipment serves as the first critical size reduction stage, directly impacting downstream efficiency.

Aliran Kerja Operasi:
1. Excavated limestone shot rock is fed via dump truck or loader into the crusher’s vibrating grizzly feeder (VGFF VGF).
2. VGF mengeluarkan denda dan memintas bahan subsaiz, directing only oversize rock to the crushing chamber.
3. Yang mantap, oscillating jaw exerts immense compressive force to break large boulders into manageable, consistently sized output.
4. Crushed material is discharged onto a main conveyor for transport to secondary crushing or stockpiling.

Skop Permohonan: Ideal for stationary primary crushing plants in largescale quarrying. Best suited for compressive strength rock under 350 MPa.

Batasan: Not designed as a mobile unit for frequent relocation. Feed size must be controlled within the crusher’s designed maximum opening.

3. CIRI TERAS

Bingkai Tugas Berat & Struktur Dikimpal | Asas Teknikal: Analisis Unsur Terhingga (FEA) pengagihan tekanan yang optimum | Faedah Operasi: Menghilangkan rekahan keletihan bingkai di bawah beban kitaran; withstands decades of highimpact forces | Kesan ROI: Memanjangkan hayat perkhidmatan struktur melebihi 20 tahun, eliminating premature capital replacement costs.

Rahang Tahan Lelasan Mati & Pinggan Pipi | Asas Teknikal: Highgrade manganese steel with optimized tooth profile geometry | Faedah Operasi: Maintains effective nip angle longer, ensuring consistent throughput and product gradation between changes | Kesan ROI: Mengurangkan kekerapan penukaran pelapik dengan 1525%, lowering parts inventory and labor hours dedicated to maintenance.

Sistem Pelarasan Togol Hidraulik | Asas Teknikal: Integrated hydraulic cylinders replace traditional mechanical shims | Faedah Operasi: Allows operators to adjust the crusher discharge setting safely in minutes versus hours, walaupun dalam keadaan kosong | Kesan ROI: Minimizes noncrushing time for product size adjustments; improves responsiveness to changing product demand.

HighStroke Elliptical Motion | Asas Teknikal: Aggressive elliptical jaw motion at the feed opening | Faedah Operasi: Promotes accelerated rock breakage at the top of the chamber, reducing bridging and improving overall throughput capacity | Kesan ROI: Meningkatkan tan diproses sejam (Tph) oleh 510% within the same machine footprint compared to standard kinematics.

Pangkalan Motor Bersepadu & Pengawal Tali Pinggang | Asas Teknikal: Unified baseplate design with fully enclosed belt guards | Faedah Operasi: Memudahkan penjajaran pemasangan, reduces site fabrication work, and enhances operator safety around drive components | Kesan ROI: Mengurangkan masa dan kos pemasangan sehingga 30% while ensuring compliance with global safety standards from day one.

Titik Greasing Berpusat & Meterai Labirin | Asas Teknikal: Singlepoint lube system for all major bearings; halangan pengedap berbilang peringkat | Faedah Operasi: Enables routine bearing lubrication in under 10 minit; effectively excludes limestone dust from bearing housings | Kesan ROI: Prevents costly bearing failures—the leading cause of unplanned crusher downtime—extending mean time between failures (MTBF) significantly.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Purata Piawaian Industri | Penyelesaian Penghancur Rahang Utama Kami | Kelebihan Berdokumen |
| : | : | : | : |
| Adanya (Masa aktif %) | 88 92% | 94 96%| +4% penambahbaikan |
| Manganese Wear Life (Juta Tan) | 0.8 1.2 MTon| 1.4 1.6 MTon| +30% penambahbaikan |
| Penggunaan kuasa (kWj/Tan) for hard limestone| 0.8 1.0 kWj/Tan| 0.65 0.75 kWj/Tan| ~20% peningkatan |
| Masa Pelarasan Tetapan Pelepasan from open to closed side| ~24 jam (mekanikal)| <15 minit (hidraulik)| ~90% penjimatan masa |

Field data based on comparative installations in comparable limestone formations.

5. SPESIFIKASI TEKNIKAL

Kapasiti Julat Model: 300 – 1,500 Metrik Tan sejam (MTPH)
Julat Pembukaan Suapan: Sehingga 1500mm x 1200mm (59" x 47")
Saiz suapan maksimum: Up to ~85% of gape width
Keperluan Kuasa Pandu: 90 kW – 250 kw (125 HP – 350 Hp), Bergantung pada model
Berat Penghancur (Bingkai & Roda tenaga): From ~25,000 kg to ~70,000 kg
Spesifikasi Bahan Utama:
Bingkai utama: Plat keluli buatan, melegakan tekanan
Rahang Mati / Pinggan Pipi: Keluli Mangan Premium (14%,18%,22%)
Aci / Galas: Keluli aloi palsu / Galas penggelek sfera
Togol plat / Beam: Ductile cast iron / Keluli aloi
Julat Suhu Operasi: 20°C hingga +45°C (4°F hingga +113°F)
Dust Mitigation: Prepared for water spray nozzle integration on VGF and feed chute

6. SENARIO APLIKASI

Operasi Pengkuarian Agregat Berskala Besar

Challenge A major Midwest producer faced escalating costs from secondary breaking and premature wear on cone crushers due to poor primary fragmentation from an aging jaw crusher.
Solution Installation of a highcapacity primary jaw crusher with an aggressive stroke profile optimized for their specific limestone geology.
Results Product gradation from the primary stage improved immediately; +12% increase in total plant throughput was achieved within one quarter due to reduced bottlenecks downstream.

Cement Plant Integrated Quarry

Challenge A cement plant needed higher reliability from its captive quarry crusher to ensure consistent raw meal supply; unplanned stops were halting kiln feed preparation.
Solution Replacement with a new generation jaw crusher featuring centralized lubrication and enhanced sealing systems specifically for highdust environments.
Results Crusher availability increased from an average of 95%. Annual maintenance labor hours dedicated to the primary station were reduced by an estimated two full weeks per year.

7. PERTIMBANGAN KOMERSIL

Our primary jaw crushers are offered in three valueengineered tiers:

1. Peringkat Kewajipan Standard: For consistent feed with moderate abrasiveness/impact risk.
2.
3.Peringkat Tugas Berat (Recommended for most limestone applications): Includes all features listed in Section III as standard.
4.ExtremeDuty Tier: For operations with highly variable feed or exceptionally hard/abrasive inclusions; includes upgraded components throughout.

Ciri pilihan termasuk sistem gris automatik, motor starters/VFDs integrated into control panels, wear monitoring systems via IoT sensors,and custom discharge conveyor flanges.Financing options include capital purchase,perjanjian pajakan milik secara langsung,and tailored service contracts covering planned maintenance,pemeriksaan,and guaranteed parts availability.Service packages are structured around guaranteed uptime agreements,supported by our global network of field service engineers specializing in mineral processing equipment

Soalan Lazim

Q What is required for foundation installation?
A Detailed civil engineering drawings are provided specific t o each model These designs account f or dynamic loads Our team offers optional site review services prior t o pour

Q How does this unit integrate int o my existing plant layout?
A Our engineering department can review your current flow sheet an d conveyor heights We provide comprehensive interface drawings t o ensure smooth integration minimizing retrofit costs

Q What is th e typical lead time f or delivery?
A Lead times vary based o n model specification an d customization Standard heavy duty models typically ship within weeks following order confirmation

Q Are training programs available f or our operations an d maintenance staff?
A Yes Comprehensive onsite training covering safe operation routine maintenance procedures troubleshooting an d liner change out protocols i s included with every installation

Q Adakah anda menawarkan jaminan prestasi?
A Yes we provide guaranteed capacity throughput based o n agreed feed material analysis along with mechanical warranties covering all major components against defects i n materials an d workmanship