1. PEMBUKAAN PAINPOINT DRIVEN

Menguruskan litar penghancur bijih besi adalah berbeza, cabaran kos tinggi. Are you facing persistent bottlenecks that limit your plant’s rated throughput? Is unscheduled downtime for liner changes and component wear eroding your production schedule and maintenance budget? Do you struggle with inconsistent product sizing, leading to downstream processing inefficiencies in grinding or beneficiation? Tambahan pula, are rising energy costs per ton of processed material directly impacting your operational margins? Isu-isu ini diterjemahkan kepada kerugian yang boleh diukur: jam pengeluaran yang hilang, excessive spare parts inventories, and suboptimal resource yield.

Soalan utama untuk pengurus kilang adalah ini: bagaimana anda boleh mencapai boleh dipercayai, hightonnage reduction of abrasive iron ore while controlling capital and operational expenditure? The solution lies in specifying a purposeengineered private label iron ore crushing plant.

2. GAMBARAN KESELURUHAN PRODUK

Produk ini adalah lengkap, modular crushing system engineered for primary and secondary reduction of magnetite, hematit, dan bijih besi lain. It is supplied as a private label solution, allowing for branding alignment while leveraging proven, heavyduty componentry.

Aliran Kerja Operasi:
1. Lambakan Utama & Grizzly: Runofmine ore is dumped onto a rugged grizzly feeder, scalping out fine material to bypass the primary crusher, meningkatkan kecekapan keseluruhan.
2. Menghancurkan Rahang Utama: A heavyduty jaw crusher performs initial size reduction, delivering a consistent feed to the secondary stage.
3. Penghancuran Kon Sekunder: The heart of the system, a highcapacity cone crusher—configured for coarse or mediumfine output—provides the final cubical product sizing critical for downstream processing.
4. Pemeriksaan & ClosedCircuit Control: Sized material is screened; oversize is recirculated back to the cone crusher in a closedloop system ensuring precise final product specification.

Skop Permohonan & Batasan:
Skop: Ideal for greenfield installations or expansion projects requiring 500 ke 2,500+ kapasiti TPH. Suited for processing hard, abrasive iron ores with compressive strengths up to 350 MPa.
Batasan: Not designed as a tertiary or quaternary stage for ultrafine grinding. Feed size must conform to crusher opening specifications. Optimal performance requires consistent feed gradation and controlled moisture content to prevent chamber packing.

3. CIRI TERAS

HeavyDuty Liner Geometry | Asas Teknikal: Computermodeled cavity profiles and highchrome white iron metallurgy | Faedah Operasi: Extended wear life by 3050% over standard manganese steel in abrasive service | Kesan ROI: Reduces liner change frequency and inventory costs, meningkatkan ketersediaan penghancur.

Advanced Chamber Clearing System | Asas Teknikal: Hydraulic or gaspowered tramp release and clearing automation | Faedah Operasi: Recovers from stall conditions in under 60 saat tanpa campur tangan manual | Kesan ROI: Prevents cascading downtime from uncrushable material, protecting downstream conveyor systems.

Centralized Greasing & Kawalan PLC | Asas Teknikal: Automated lubrication intervals tied to bearing temperature and operating hours | Faedah Operasi: Ensures optimal bearing health and eliminates manual greasing errors | Kesan ROI: Memanjangkan hayat perkhidmatan galas utama sehingga 40%, mengurangkan risiko kegagalan bencana.

Reka Bentuk Skid Modular | Asas Teknikal: Preassembled structural steel skids with integrated walkways and maintenance platforms | Faedah Operasi: Reduces onsite civil works and installation time by an estimated 40% | Kesan ROI: Lowers total installed cost (TIC) and accelerates timetoproduction.

Pemacu Frekuensi Boleh Ubah (VFD) Keserasian | Asas Teknikal: Crusher motor integration with plantwide process control systems | Faedah Operasi: Allows realtime adjustment of crusher speed/throw to match feed conditions for optimal power draw and product shape | Kesan ROI: Achieves energy savings of 1015% under variable load conditions versus fixedspeed operation.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (AggregateFocused Plant) | Private Label Iron Ore Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Kehidupan Pakai Pelapik (Bijih Pelelas) | ~450,000 tan setiap set (Mangan) | ~650,000 tons per set (Special Alloy) | +44% |
| Ketersediaan Sistem (Dijadualkan) | ~92% (termasuk. Perubahan pelapik) | ~95% (termasuk. Perubahan pelapik) | +3 Mata Peratusan |
| Penggunaan Kuasa setiap Tan Diproses| Garis dasar (100%)| Ruang yang dioptimumkan & drive = ~90% of baseline |10% |
| Pemasangan & Masa Pentauliahan| 810 weeks on site| 56 weeks on site (modular)| 30% |
| Product Fines (10mm) Kawalan| Biasanya 1822% of output| Chamber optimization yields 1518% of output| 20% reduction in unwanted fines |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 500 TPH berakhir 2,500 TPH nominal throughput of taconite ore.
Keperluan kuasa: Penghancur utama: 150400 kw; Penghancur sekunder: 250600 kw; Total System Feeders/Conveyors/Screens: Additional 300800 kW dependent on configuration.
Spesifikasi Bahan: Primary wear liners in premium manganese steel; Secondary chamber liners in highchrome white iron (27% Cr). Structural steel is Grade S355JR with abrasionresistant plate in highwear zones.
Dimensi Fizikal (Skid Biasa): Secondary crushing module approx. L12m x W6m x H7m. Jejak tumbuhan penuh berbeza-beza mengikut konfigurasi.
Julat Operasi Persekitaran: Designed for ambient temperatures from 25°C to +45°C with optional heating/cooling packages. Dust suppression system integrated as standard.

6. SENARIO APLIKASI

Pengembangan Penumpu Magnetit Greenfield

Cabaran:
A major mining operator needed to expand concentrator throughput but was constrained by existing primary crushing capacity producing inconsistent feed size for new SAG mills.
Penyelesaian:
Implementation of a turnkey private label iron ore crushing plant as a parallel primary/secondary circuit specifically calibrated for their magnetite ore characteristics.
Keputusan:
Mencapai peningkatan daya pengeluaran yang berterusan sebanyak 1,800 TPH at a consistent 25mm product size. Mill feed stability improved grinding circuit efficiency by an estimated 8%, contributing directly to higher concentrate output.

Lifecycle Replacement in Hematite Operation

Cabaran:
An aging fleet of disparate crushers led to high maintenance costs (~20% of annual OPEX), poor availability (94%.

7. PERTIMBANGAN KOMERSIL

Peringkat Harga: Offered across three standardized capacity tiers—Medium Duty (1,800 Tph)—with corresponding component specifications.
Ciri Pilihan: Upgrades include advanced predictive monitoring sensors (getaran/suhu), automated wear measurement systems, hybrid diesel/electric power modules for remote sites,
and enhanced dust encapsulation packages.
Pakej Perkhidmatan: Tiered annual support agreements are available covering scheduled maintenance inspections,
kajian analitik ramalan,
and priority parts provisioning with guaranteed dispatch times.
Pilihan Pembiayaan: Flexible capital expenditure solutions can be structured including equipment leasing models,
project financing linked to production milestones,
or traditional purchase agreements.

8.Soalan Lazim

S1:
Are these private label plants compatible with our existing conveying infrastructure?
A1:
Yes.The modular design allows engineering interfaces
(ketinggian pelepasan,
feed chute orientations)
to be customized during the design phase
to integrate with your current stockpile conveyors
or downstream process feed points.Field surveys are conducted
to ensure dimensional compatibility prior
to fabrication

S2:
Apakah kesan operasi yang dijangkakan semasa pentauliahan?
A2:
Our phased commissioning protocol minimizes disruption.Crushing modules are pretested at our facility.Onsite commissioning typically requires two weeks
of planned integration downtime followed by one week
of rampup under supervision until design capacity is met

S3:
How does the pricing compare
to sourcing major OEM equipment directly?
A3:
The private label model typically offers capital cost savings between fifteen percent without compromising critical component quality.We achieve this through optimized global supply chain logistics
for structural components while utilizing tierone suppliers
for all mechanical drive
and wear parts

S4:
What are the lead times from order placement
to delivery?
A4:
For standard capacity configurations lead time ranges from twentysix weeks depending on current manufacturing schedule.Complex customizations may extend this timeline which will be defined during project scoping

S5:
Is training provided for our operations
and maintenance teams?
A5:
Comprehensive training is included covering safe operation routine maintenance procedures troubleshooting guides specific documentation review conducted both at your site during commissioning

S6:
Apakah syarat jaminan yang dikenakan?
A6:
The complete structure carries standard warranty.All major mechanical components including crusher main frames shafts bearings motors carry manufacturer warranties which we manage on your behalf providing singlepoint support

S7:
Can this plant handle variations in ore hardness within our deposit?
A7：
The hydraulic adjustment systems on both jaw cone crushers allow operators adjust closed side settings compensate variations hardness maintain consistent product size PLC control system can automate adjustments based power draw maintaining optimal performance across different ore zones