H1: ODM Stationary Crushing & Loji Saringan: Kejuruteraan untuk Masa Operasi Maksimum dan Tan

1. Addressing Your Core Operational Challenges in Aggregate Production

Managing a fixed crushing site presents distinct, cabaran yang mahal. Downtime isn't just lost production; it's missed contracts and eroding margins. Adakah anda menghadapi:
Penghentian Tidak Dirancang: Kegagalan galas, sekatan penghancur, and conveyor issues can halt your entire line. Every hour of downtime can cost thousands in lost revenue and idle labor.
Produk Akhir yang tidak konsisten: Fluctuations in feed material or improper calibration lead to offspec aggregate, mengakibatkan penolakan produk, kos rerushing, dan merosakkan hubungan pelanggan.
Kerumitan Penyelenggaraan Tinggi: Disjointed equipment from multiple suppliers creates a spare parts nightmare and extends maintenance windows, straining your operational budget.
Aliran Bahan Tidak Cekap: Bottlenecks between crushing stages or screening units cap your plant's true capacity, forcing you to run longer hours at higher cost per ton.
Kos operasi yang semakin meningkat: Pemacu yang tidak cekap tenaga, penggunaan bahagian haus yang berlebihan, and high manual labor for monitoring directly reduce your profitability per cubic meter.

The question is not just how to crush rock, but how to build a reliable, predictable production asset. The solution lies in a fully integrated system designed from the ground up for synchronized performance.

2. Gambaran Keseluruhan Produk: The Integrated Stationary Crushing & Loji Saringan

The ODM Stationary Crushing & Screening Plant is a complete, hardwired processing circuit engineered for highvolume aggregate production in quarrying and mining applications. It transforms raw feed (0800mm) into precisely graded final products (mis., 05pasir mm, 520agregat mm).

Aliran Kerja Operasi:
1. Pemakanan Utama & Menghancurkan: Dump trucks feed a vibrating grizzly feeder which removes fines and directs oversize to a robust primary jaw crusher for initial size reduction.
2. Pemprosesan Pertengahan & Pemeriksaan: Crushed material is conveyed to a secondary cone crusher for further reduction. Output is then routed to a multideck vibrating screen for classification.
3. Pengisihan Produk & Stok: Onspec material from each screen deck is conveyed to designated stockpiles. Oversize is recirculated back to the appropriate crusher in a closedcircuit loop.

Skop Permohonan: Ideal for hightonnage production of aggregates for concrete, asfalt, and road base. Suitable for processing granite, basalt, batu kapur, and other abrasive ores.

Batasan: This is a fixedinstallation solution requiring foundational concrete works and grid power connection. Ia tidak direka untuk penempatan semula yang kerap.

3. Ciri Teras: Engineering Meets Operational ROI

Modular Structural Frame | Asas Teknikal: pasang siap, hightensile steel sections with machined connection points | Faedah Operasi: Membolehkan lebih cepat, more precise onsite installation with reduced crane time and foundation work | Kesan ROI: Cuts installation timeline by up to 30%, reducing timetorevenue.

Sistem Kawalan PLC Berpusat | Asas Teknikal: Pengawal Logik Boleh Aturcara dengan antara muka mesin manusia (HMI) panel | Faedah Operasi: Allows singleoperator monitoring and control of the entire flow from feeder to final conveyor; provides diagnostic alerts | Kesan ROI: Reduces labor requirements by approximately 1 FTE per shift while improving response time to anomalies.

HeavyDuty Vibrating Screen with QuickDeck Change | Asas Teknikal: Rubbermounted screen box with tensioned wedgewire or polyurethane panels | Faedah Operasi: Minimizes vibration transfer to structure; allows screen media replacement in hours vs. hari | Kesan ROI: Increases annual availability by ~2% and reduces maintenance labor costs.

Crusher Cavity Optimization | Asas Teknikal: Computeraided design of crushing chamber geometry matched to expected feed material | Faedah Operasi: Maximizes reduction ratio per pass, improves product shape (kubis), and promotes even wear liner utilization | Kesan ROI: Boosts throughput by 515% while extending wear part life cycles.

Penindasan Debu & Sistem Penahanan | Asas Teknikal: Strategically placed spray nozzles at transfer points with encapsulation skirts | Faedah Operasi: Mengekalkan pematuhan peraturan untuk pelepasan zarah; protects bearings and motors from dust ingress | Kesan ROI: Avoids regulatory fines and reduces premature bearing failures by an estimated 40%.

Layered Walkways & Platform Penyelenggaraan | Asas Teknikal: Full perimeter access with safety handrails integrated into the plant design | Faedah Operasi: Enables safe visual inspections, routine greasing, and component servicing without specialized scaffolding | Kesan ROI: Promotes proactive maintenance culture; reduces risk of safety incidents and associated downtime/costs.

4. Kelebihan Kompetitif: Keuntungan Prestasi Boleh Dikira

| Metrik Prestasi | Penanda Aras Piawaian Industri | ODM Stationary Plant Solution | Kelebihan Berdokumen |
| : | : | : | : |
| Ketersediaan Loji (Masa Jalan yang Dijadualkan) | 9092% | 9496%| +4% Penambahbaikan |
| Penggunaan Tenaga setiap Tan Diproses| Berbeza mengikut jenis batu| Optimized motor loads & pemacu yang cekap| Hingga 12% Pengurangan |
| Kos Bahagian Pakai setiap Tan Metrik| $0.85 $1.10 USD| Matched chamber design & pemilihan aloi| 1520% Pengurangan |
| Pemasangan & Masa Pentauliahan| 810 minggu (from foundation)| Modular frame & unit yang telah dipasang sebelumnya| ~30% Faster (67 minggu)|
| Required Operating Labor per Shift| 34 Personnel| Centralized PLC control system| Dikurangkan dengan 1 Operator |

5. Spesifikasi Teknikal

Julat Kapasiti Reka Bentuk: 200 800 Tph (configurable based on model).
Keperluan Kuasa Utama: 400V/50Hz atau 480V/60Hz; Jumlah Kuasa yang Dipasang: 350kW 800kW.
Spesifikasi Bahan Utama:
Pelapik penghancur: Keluli mangan (14%,18%,22%) or Chrome Iron Alloy options.
Dek Skrin:Tensioned Polyurethane or HighCarbon Steel Wire Mesh.
Belting Penghantar:Synthetic Fabric Ply (EP630/3) with minimum 12mm top cover.
Keluli Struktur:S355JR grade with hotdip galvanized finish on walkways.
Typical Physical Footprint (for a 350TPH plant): ~35m (L) x 22m (W) x 15m (H).
Julat Operasi Persekitaran: Ambient temperature 20°C to +45°C; tahap pelepasan habuk mematuhi <10mg/Nm³ standards when used with suppression system.

6. Senario Aplikasi

Projek Pembesaran Kuari Granit

Cabaran:A quarry needed to increase output by over 60% but had limited space for plant expansion within their existing lease boundary.Solution:Kompak,OEMdesigned threestage crushing circuit was installed,fitting into the footprint of an older twostage plant.The design included a large primary jaw crusher followed by two secondary cone crushers in parallel configuration feeding shared screens.This allowed higher throughput without increasing land use.The centralized control system was integrated into their existing site office via fiber optic cable.The new layout reduced internal haulage distances significantly.Retrofitted spray systems kept dust under control during blasting operations near residential areas.Finally,the modular construction allowed commissioning during planned seasonal shutdown minimizing disruption.Financing was secured through an equipment lease agreement preserving capital for other site improvements.Regular service visits ensured optimal performance throughout the warranty period leading them purchase an extended coverage plan.This holistic approach transformed their operational constraints into competitive advantage securing several large infrastructure contracts previously out reach due capacity limitations

Pemprosesan Batu Kapur untuk Makanan Loji Simen

Cabaran:A cement producer required consistent 25mm feed for their raw mill,but variations in quarry moisture content caused frequent clogging in their existing impact crusher.Solution:The implementation featured a primary jaw crusher followed by a heavyduty cone crusher equipped with automated setting regulation.Air cannons were installed at key hopper points,and conveyor skirts were extended.The PLC system was programmed to adjust feeder speed based on crusher motor load.Field data after six months showed clogging events reduced by over95%.Product consistency improved dramatically meeting the 25mm spec99.%of the time.This reliability allowed the cement kiln department optimize their own processes knowing raw material supply would be uninterrupted

Kitar Semula Projek Infrastruktur Bandar

Cabaran:A major road construction project mandated onsite recycling of demolished concrete to reduce truck traffic environmental impact but faced strict noise dust regulations tight urban site.Solution:A semimobile configuration was deployed featuring extensive acoustic enclosures around all major noise sources like crushers screens fully enclosed conveyors waterbased dust suppression systems every transfer point.The plant processed over500000tons recycled concrete aggregate meeting all stringent local environmental standards avoiding thousands truck movements city center

Pertimbangan Komersial

Pricing is structured around plant capacity,customization level,and chosen component brands(e.g.,crusher motor manufacturer).Kami menawarkan tiga peringkat utama:

1.Tahap Konfigurasi Asas:Covers core functionality standard components proven reliability suitable budgetconscious operations seeking essential performance.Pricing typically ranges from$750000to$1million USD depending capacity

2.Peringkat Prestasi(Disyorkan):Includes features like centralized PLC automation premium wear liners enhanced dust suppression walkways platforms.Pricing typically ranges from$ million$ million USD

3.Tahap Premium Turnkey:Fully customized solution including advanced predictive monitoring sensors extended warranty comprehensive operator training package civil engineering drawings support.Pricing determined specific project scope

Peningkatan Ciri Pilihan:
Advanced vibration monitoring sensors critical bearings
Sistem pelinciran automatik
Overband magnetic separator ferrous metal removal
Additional finished product conveyor stackers
Kit permulaan alat ganti

Pakej Sokongan Perkhidmatan:
Standard Warranty months parts labor excluding wear items
Extended Coverage Plans years available purchase
Annual Maintenance Contracts include scheduled inspections priority technical support discounted spare parts
OnDemand Field Service Technician dispatch available global network partners

Pilihan Pembiayaan:
We work accredited financial partners offer:
Equipment leasing structures preserve working capital
Term loans competitive rates project financing
RentaltoOwn programs lower initial commitment

Bahagian Soalan Lazim

What if my feed material hardness changes frequently?
Our cone crushers recommended Performance Tier feature hydraulic adjustment CSS clearing allow quick adaptation different rock characteristics without stopping process ensuring consistent output quality varying conditions

How does this integrate existing equipment like my primary excavator loaders?
Plants designed flexible feeding arrangements accommodate different loading methods We provide interface specifications hopper heights capacities ensure compatibility your current loading fleet minimizing integration issues

Apakah pentauliahan penghantaran masa utama yang tipikal?
For standard configurations lead time typically weeks exworks following deposit receipt Site commissioning supervised our engineers requires approximately weeks depending complexity local readiness

Adakah alat ganti tersedia secara global?
Yes maintain strategic inventory critical components partner global logistics providers ensure expedited shipping Additionally provide detailed part numbers crossreferences equivalent items facilitate local sourcing noncritical parts where appropriate

Adakah anda menawarkan latihan pengendali?
Yes comprehensive training included Turnkey Tier optional others covers normal operation routine maintenance troubleshooting safety procedures Training conducted both our facility yours ensure competence confidence your team