1. PEMBUKAAN PAINPOINT DRIVEN

Adakah anda menguruskan operasi agregat volum tinggi dan menghadapi kesesakan berterusan yang menghakis keuntungan? Untuk pengurus loji dan kontraktor kejuruteraan, loji penghancur batu 250300tph adalah aset pengeluaran yang kritikal, namun prestasinya secara langsung menentukan keuntungan anda. Cabaran biasa termasuk:

Masa Henti Tidak Berjadual: Frequent mechanical failures in key crushers or screens halt your entire line, menelan belanja ribuan sejam dalam pengeluaran yang hilang dan buruh terbiar.
Kualiti Produk Akhir yang tidak konsisten: Fluctuations in grain size and shape, often due to improper crushing chamber dynamics or worn liner profiles, lead to product rejection and diminished market value.
Kos Operasi Berlebihan: Skyhigh energy consumption from inefficient drives and conveyors, combined with the rapid wear of components not suited for your specific feed material, creates unsustainable operating expenses.
Complex Material Flow & Kemacetan: Poorly designed transfer points, undersized hoppers, and mismatched conveyor speeds create blockages and reduce system throughput below designed capacity.
Skalabiliti & Had Fleksibiliti: A rigid plant layout cannot adapt to changing feed material hardness or market demand for different aggregate specifications, locking you into a single product strategy.

How do you transition from reactive maintenance to predictable production? What does it take to achieve a true 300tph nominal capacity with consistent quality and controlled costs? The answer lies in a professionally engineered 250300tph stone crushing plant design service.

2. GAMBARAN KESELURUHAN PRODUK

This service provides a complete, turnkey design package for a stationary or semistationary stone crushing plant engineered for a nominal output of 250 ke 300 Ton metrik sejam. The design encompasses the entire comminution and sizing circuit, from primary feed to final product stockpiling.

Aliran Kerja Operasi:
1. Penghancuran utama & Memberi makan: Dump trucks discharge feed material into a largecapacity vibrating grizzly feeder, which scalps out undersize material and steadily feeds the primary jaw crusher.
2. Sekunder & Pengurangan Tertiari: Primary crushed material is conveyed to secondary crushing stage (typically a cone crusher) untuk pengurangan saiz selanjutnya. A tertiary cone crusher or vertical shaft impactor (Semua orang) may be incorporated for precise shaping and fine crushing.
3. Saiz & Pengelasan: Crushed material is routed through multideck vibrating screens to separate it into specified aggregate fractions (mis., 05mm, 510mm, 1020mm).
4. Recirculation & Stok: Oversize material from screens is recirculated back to the appropriate crusher in closedcircuit design. Onspecification aggregates are conveyed to designated stockpile conveyors for radial stacking.

Skop Permohonan & Batasan:
Skop: Ideal for granite, basalt, batu kapur, and other mediumtohard abrasiveness rocks. Suitable for largescale quarry operations, projek infrastruktur utama (lebuh raya, Keretapi), and commercial concrete/asphalt aggregate supply.
Batasan: Not designed for very soft materials like chalk without specific modifications. Feed size is typically limited by primary crusher opening (mis., ≤750mm). Plant footprint requires significant prepared site area.

3. CIRI TERAS

Reka Bentuk Struktur Modular | Asas Teknikal: Boltconnected heavyduty steel modules with preengineered support points | Faedah Operasi: Enables faster onsite installation and future reconfiguration or expansion with minimal foundation work | Kesan ROI: Reduces civil engineering costs by approximately 15% and shortens commissioning time by up to 20%.

Intelligent Crushing Chamber Optimization | Asas Teknikal: Crusher selection and chamber profiles are digitally simulated based on your specific feed material sample analysis | Faedah Operasi: Maximizes reduction ratio per stage while minimizing wear part stress and power draw | Kesan ROI: Increases liner life by an estimated 2540%, secara langsung mengurangkan kos inventori alat ganti.

Kawalan PLC Berpusat & Sistem Pemantauan | Asas Teknikal: Pengawal Logik Boleh Aturcara dengan antara muka mesin manusia (HMI) providing realtime data on power consumption, production rates, and machine health | Faedah Operasi: Allows operators to optimize feed rates remotely and receive predictive maintenance alerts | Kesan ROI: Improves overall operational efficiency by up to 12% through coordinated control and prevents catastrophic failures.

HeavyDuty Conveyor System with Load Regulation | Asas Teknikal: Pemacu frekuensi boleh ubah (VFDS) on key conveyors synchronized with crusher amp draw sensors | Faedah Operasi: Prevents belt overloading at transfer points and optimizes power use across the line | Kesan ROI: Reduces belt wearrelated downtime by an estimated 30% and lowers energy consumption of the conveying system.

Penindasan Habuk Bersepadu & pembendungan | Asas Teknikal: Strategically placed spray nozzles at transfer points coupled with baghouse filter systems on crusher outlets as an option | Faedah Operasi: Maintains regulatory compliance for particulate emissions while protecting machinery health | Kesan ROI: Mitigates risk of environmental fines and reduces internal component abrasion from dust.

Optimized Vibrating Screen Selection | Asas Teknikal: Screen deck size, slope, vibration frequency/amplitude are calculated based on required cut points and moisture content of material | Faedah Operasi: Achieves high screening efficiency (>95%) ensuring product specification consistency without overloading the screen surface | Kesan ROI: Minimizes recirculating load wastefully passing through crushers again saving energy reducing wear

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Reka Bentuk Piawaian Industri | Our Professional Stone Crushing Plant Design Service | Kelebihan (% Penambahbaikan) |
|||||
| Keseluruhan Ketersediaan Loji | ~85% | Designed for ≥92% | +8% |
| Penggunaan Tenaga setiap Tan | Berbeza secara meluas; often suboptimal | Systemlevel optimization targeting reduction | Hingga 15% |
| Kos Pakai setiap Tan (Peringkat Utama) | Based on generic liner selection | Materialspecific chamber design | Hingga 35% |
| Kecekapan Saringan (critical sizes)| ~90% |>95% | +5%+ |
| Pemasangan & Masa Pentauliahan | Subject to site delays Streamlined modular design reduces field work Up to 25%

5. SPESIFIKASI TEKNIKAL

Julat kapasiti nominal: 250 – 300 Ton metrik sejam (berbeza-beza berdasarkan kekerasan bahan suapan & Pengagihan saiz).
Pilihan Penghancur Utama: Kursus rahang (900x1200mm minimum recommended) atau Gyratory Crusher.
Penghancur sekunder/tertiari: Penghancur Kon Hidraulik (singlecylinder or multicylinder models) configured in closed circuit.
Stesen Saringan: Skrin bergetar tugas berat berbilang dek (biasanya 23 unit), sizes ranging from 2.4m x 6m upwards.
Keperluan Kuasa (Dianggarkan): Jumlah kuasa terpasang lebih kurang 550 – 700 kW dependent on circuit complexity inclusion of VSI
Spesifikasi Bahan Utama: Primary structural steel Q345B; Conveyor belting minimum EP630/4; Crusher liners high manganese steel or chrome iron alloys as specified
Jejak Tumbuhan Biasa: L x W approx.:150m x80m including stockpile areas subject final layout
Julat Operasi Persekitaran: Designed ambient temperature 20°C +45°C; dust emission compliant with <50mg/Nm³ standard

6 SENARIO APLIKASI

Granite Quarry Expansion Challenge Specific problem Existing twostage plant could not exceed190tph creating bottleneck preventing bidson large road contracts Solution Implementation new threestage250300tphstonecrushingplantdesign featuringjawcrusher secondary tertiarycone crushersinclosedcircuitwithhighefficiencyscreens Results Achievedsteadystateproductionof280tphofhighqualityaggregatesforasphalt Resultedinwinningtwo majorhighwayprojectsincreasingannualrevenuebyanestimated35%

Limestone Processingfor Cement Plant Feed Challenge Inconsistentfinesproductionandexcessivewearinhammercrushersleadingtohighmaintenancecostsandunreliablefeedforthekiln Solution Designed250tphstonecrushingplantwithprimaryjawcrusherandsecondarytertiaryimpactcrushersfocusedonshapingandfinesgeneration integratedwithadvanceddustcollection Results Productgradationachievedover98consistencymeetingcementrawmixspecifications Wearpartlifedoubledcomparedtoprevioussystem reducingmaintenancehoursby60permonth

7 PERTIMBANGAN KOMERSIL

Our professional stone crushing plant design service is offered in structured tiers:

1. Basic Design Package Includes process flow diagram PFD general equipment list GEL preliminary layout drawings foundation load data
2 Detailed Engineering Package All Basic items plus piping instrumentation diagrams PID detailed structural drawings electrical schematics control philosophy comprehensive billofquantities BOQ
3 Turnkey Project Management Package Full Detailed Engineering plus procurement support factory acceptance testing FAT supervisionofinstallation commissioning SAT

Optional Features Advancedautomationsystems remotemonitoringcapabilities complete dustsuppressionbaghouses noiseenclosures customcolor schemes branding

Service Packages Annual maintenance contracts spare parts provisioning agreements operator training programs available

Financing Options We can facilitate introductions topartnerfinancial institutionsfor equipment leasingor project financing solutions subjectto credit approval

8 Soalan Lazim

Q What information do you need provide accurate stonecrushingplantdesign
A We require geological reportsofyour reservematerial samplesfor testingabrasiveness compressive strength desired finalproduct specificationsanddetailed siteplanwithtopographical information

Q How does thisdesign addressinteroperabilitywithmyexistingequipment
A Thedesign servicecanbe scopedtointegratewithyourexistingprimarycrusher screensorconveyors providedwe receivecomplete datasheetsandconductsiteassessment ofthecurrentassets

Q Whatisthetypicaltimelinefromfinalizeddesigntooperationalplant
A Fora greenfield installation leadtime formajorequipmentis69months Siteconstruction mechanical erection typicallyrequires34months dependingoncomplexity weatherconditions

Q Arethepredictedcapacityfiguresguaranteed
A Nominalcapacityisbasedonstandardizedtestingofyourmaterial samples Performanceguaranteesareprovidedinthesupplycontractsubjectto agreedfeedmaterial specificationsandoperatingparameters

Q Whatistheexpectedimpactonourworkforce
A Thedesignedplant emphasizesoperator safetyandergonomics Trainingisprovidedtoensureyourexistingstaffcanmanagethe moresophisticatedcontrolsystems effectivelyoftenleadingtohigherjob satisfaction

Q Canyoudesignformultipleproductsimultaneously
A Yes themultideckscreening setupandclosedcircuitcrusherconfigurationare specificallyengineeredtoproduce34different aggregatesizes concurrently maximizingproductvaluefromsinglefeedstock