1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang semakin meningkat dan ketersediaan yang tidak dapat diramalkan menghakis margin pemprosesan bijih besi anda? Untuk pengurus loji dan kontraktor kejuruteraan, the primary crushing stage is a critical bottleneck with direct consequences for your entire operation. Cabaran biasa termasuk:

Masa Henti Berlebihan untuk Penyelenggaraan: Perubahan pelapik yang kerap dan pembaikan tidak dirancang pada penghancur utama anda menghentikan keseluruhan sistem suapan, menelan belanja beribu-ribu sejam dalam pengeluaran yang hilang.
Kos Bahagian Pakai Tinggi & Penggunaan: Abrasive iron ore rapidly degrades crusher components, leading to unsustainable spending on manganese steel and arduous, laborintensive replacement cycles.
Pengurangan Saiz Suapan Tidak Konsisten: Fluctuations in feed size or hardness can cause choke feeding or cavity flooding, reducing throughput and creating downstream processing instability.
Rigid Plant Layout Constraints: Fixed primary crushing stations lack mobility, complicating mine plan progression and requiring costly overburden removal or lengthy rehandling.

Is your current solution equipped to handle increasingly hard and abrasive ore bodies while maintaining costpertonne targets? A strategically selected private label iron ore crushing plant provides a tailored answer to these systemic challenges.

2. GAMBARAN KESELURUHAN PRODUK

A private label iron ore crushing plant is a heavyduty, semistationary or modular primary crushing system engineered specifically for the highvolume, highabrasion reduction of runofmine (ROM) bijih besi. These plants are manufactured under contract to meet precise operational specifications and are branded for the distributor or large contractor.

Aliran Kerja Operasi:
1. Penerimaan ROM & PraSkrining: Direct dump from haul trucks onto a robust grizzly or scalping screen to bypass subfines material.
2. Pengurangan saiz utama: Oversize material is conveyed to a highcapacity jaw crusher or gyratory crusher for initial reduction to a manageable transport size (biasanya <250mm).
3. Primary Stockpiling: Crushed product is conveyed to a live stockpile, providing crucial surge capacity for downstream processing circuits.

Skop Permohonan: Ideal for greenfield site development, dedicated processing lines for specific ore types, or as a supplemental primary station for existing operations. Best suited for operations with a defined mine life and consistent feed characteristics.

Batasan: Not designed as portable trackmounted units for frequent relocation. Maximum efficiency is achieved with proper feed control and consistent ore geology. Requires foundational civil works and integration engineering.

3. CIRI TERAS

Rangka Penghancur Tugas Berat | Asas Teknikal: Analisis Unsur Terhingga (FEA) pengagihan tekanan yang optimum | Faedah Operasi: Menghilangkan rekahan keletihan bingkai di bawah beban kejutan daripada bahan yang tidak boleh dihancurkan | Kesan ROI: Mengurangkan risiko kegagalan struktur bencana, extending asset service life beyond 10+ tahun

Sistem Aliran Bahan Tahan Lelasan | Asas Teknikal: Hardox® or equivalent wear steel in hoppers, skirt, and chutes; ceramic lagging on critical pulley faces | Faedah Operasi: Dramatically reduces material adherence and wearthrough in transfer points | Kesan ROI: Cuts maintenance welding/replacement frequency by up to 60%, lowering direct labor and parts costs

Kawalan Automatik Berasaskan PLC & Pemantauan | Asas Teknikal: Centralized programmable logic controller with loadsharing algorithms and remote telemetry capability | Faedah Operasi: Optimizes crusher power draw, prevents choke events, dan menyediakan data operasi masa nyata | Kesan ROI: Meningkatkan konsistensi daya pemprosesan mengikut anggaran 812% while enabling predictive maintenance scheduling

Penghantar Modular & Reka Bentuk Laluan | Asas Teknikal: Bolttogether sections with standardized dimensions | Faedah Operasi: Enables faster installation onsite and allows future reconfiguration as mine layout evolves | Kesan ROI: Reduces initial construction time/cost by approximately 1520% versus fully welded structures

Pelincir Berpusat & Sistem hidraulik | Asas Teknikal: Singlepoint lubrication lines to all major bearings; dedicated hydraulic power unit for crusher adjustment/clearing | Faedah Operasi: Simplifies routine servicing intervals and enhances operator safety during maintenance tasks | Kesan ROI: Decreases scheduled maintenance downtime windows by an average of 30%

Manifold Penindasan Habuk Bersepadu | Asas Teknikal: Nozzle system plumbed into primary transfer points, tied to conveyor operation sensors | Faedah Operasi: Actively controls dust at source, improving site visibility and compliance with environmental regulations | Kesan ROI: Mengurangkan risiko denda kawal selia dan mengurangkan kos pembersihan

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Tumbuhan Generik) | Private Label Iron Ore Crushing Plant Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Kehidupan Pelapik (Mn Steel)| 450,000 550,000 tan| 600,000 750,000 tan| +25% ke +35% |
| Masa Min Antara Kegagalan (MTBF)| ~720 jam| ~1,100 hours| +53% |
| Tonnage Throughput Consistency| ±15% variance from target| ±7% variance from target| >50% improvement in stability |
| Tempoh Pemasangan Di Tapak| 1216 minggu| 810 minggu| ~33% reduction |
| Penggunaan Kuasa Khusus| Penanda aras = 100%| Mencapai 9295% of benchmark| 58% peningkatan dalam kecekapan tenaga |

5. SPESIFIKASI TEKNIKAL

Penilaian Kapasiti: Boleh dikonfigurasikan daripada 1,200 ke atas 3,500 tan sejam (Tph), based on crusher selection.
Pilihan Penghancur Utama: Penghancur rahang togol tunggal (1.2m x 1.5m up to 1.6m x 2.0m) atau Penghancur Gyratory Utama (4265 julat).
Keperluan kuasa: Total installed power typically between 450kW 900kW depending on configuration; supplied at either 6.6kV or medium voltage.
Spesifikasi Bahan: Keluli karbon struktur utama ASTM A36; wear surfaces Hardox® 450/500; crusher liners ASTM A128 Manganese Steel.
Dimensi Fizikal (tipikal): Footprint approximately 25m L x 18m W x 15m H (excluding feed ramp and discharge stockpile).
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C; dust protection rating of IP65 for electrical enclosures.

6. SENARIO APLIKASI

Direct Feed Hematite Operation

Cabaran: An existing hematite operation used a legacy crusher located far from the new pit face, requiring doublehandling by loaders and incurring high hourly equipment rental costs.
Penyelesaian: Implementation of a private label iron ore crushing plant with a deeppit receiving hopper adjacent to the new pit rim.
Keputusan: Elimination of loader rehandling reduced operating costs by approximately $0.85 per tonne hauled. The plant achieved design throughput within two weeks of commissioning.

Pengembangan Penumpu Magnetit

Cabaran: A magnetite concentrator needed to increase primary crushed tonnage by over onethird but had limited space within the existing fixed infrastructure footprint.
Penyelesaian: Deployment of a modular private label crushing plant designed with vertical stacking conveyors to fit the constrained site layout.
Keputusan:The modular design reduced civil works by an estimated $300k USD compared to traditional construction.The expansion was completed during a planned twoweek shutdown with no further production delays.

HighAbrasion Banded Iron Formation

Cabaran:A new BIF deposit exhibited higherthanaverage abrasiveness index values,causing premature failure of conveyor belts,crusher liners,and chutes in test runs using standard equipment.
Penyelesaian:A bespoke private label solution featuring enhanced wear packages,a slowerspeed jaw crusher configuration,and specialized impact beds on all transfer points.
Keputusan:Liner life improved by over onethird against initial projections.Conveyor belt replacement intervals extended from six months back toward standard ninemonth cycles,saving $120k annually in belt costs alone.

7.PERTIMBANGAN KOMERSIL

Equipment pricing tiers are structured around core crusher selection:

Peringkat I(HighCapacity Jaw Crusher Based):For midrange tonnage requirements.Capital cost range:$2M$4M USD depending on options.
Tahap II(Primary Gyratory Crusher Based):For maximum throughput (>2，500 Tph)dan keras，abrasive ores.Capital cost range:$4M$7M USD depending on options.

Ciri Pilihan:
OnBoard Power Generation Package
Pemantauan Saiz Zarah Lanjutan(PSM)Sistem
Sistem Pelinciran Automatik
Full Perimeter Dust Containment Skirting

Pakej Perkhidmatan:
Pentauliahan & Latihan Operator(Standard)
Pemeriksaan Tahunan & Parts Kitting Agreement
FullService Maintenance Contract with guaranteed uptime SLA

Pilihan Pembiayaan:
Available through partner financial institutions including operating lease structures，capital leasetoown plans，or projectbased financing tailored for mining developments.This allows preservation of capital while securing critical production infrastructure.

8.Soalan Lazim

Q:What level of customization is possible with a private label plant versus an OEM standard model?
A：Significant customization is core to the value proposition.You can specify crusher manufacturer，drive motor suppliers，conveyor belt grade，control system brand（e.g.,Siemens，AllenBradley），and structural details like access stair placement.This ensures compatibility with your existing spares inventory和maintenance practices。

Q：How does this solution integrate with my existing secondary crushing circuit和downstream processing？
A：The plants are engineered based on your required final product size（typically 250mm）for optimal secondary circuit feed.Design parameters include discharge height，conveyor speed和transfer point geometryto match your existing receiving hoppers或stockpile conveyors seamlessly。

Q：What are the lead times from order placementto commissioning？
A：Lead times vary but typically range from32to48weeksfor complete plants.This includes detailed engineering，pembuatan，shop assembly testing，dismantlementfor shipment和reassemblyon your site。Pilihan terpantas mungkin tersedia。

Q：Bolehkah anda memberikan jaminan prestasi？
A：ya。Performance guaranteesfor throughput capacity based on agreed feed material specificationsand product sizeare standardin contracts。Wear rate guaranteesfor key components like linerscan also be structuredbased on agreed abrasiveness indices。

Q：Who holds responsibilityfor equipment warranties？
A：The private label dealer holds ultimate responsibilityfor warranty administration。Components are coveredby their original manufacturer's warranties（e.g.,crusher,galas,motors），while structuraland assembly workmanshipis warranted directlyby the fabricator under our singlepoint accountability。

Q：What trainingand documentationare provided？
A：Comprehensive documentation包括asbuilt drawings,P&ID，electrical schematics，parts manuals和lubrication schedules。Onsite trainingfor operationsand maintenance crews is conductedduring commissioningwith both classroomand handson modules。

Q：Are these plants suitablefor remote locationswith limited service support？
A：ya。They are designedwith serviceabilityas apriority。Common component standardization,easy access platformsand designedin service tool clearances reduce required skill levelsfor routine tasks。Remote monitoring capabilityallows our support teamsto assistwith diagnosticsoffsite。