1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing a highvolume aggregate production site and facing persistent bottlenecks that erode profitability? Untuk pengurus loji dan kontraktor kejuruteraan, a 250300 tph stone crushing plant is a critical asset, namun konfigurasi standard sering memperkenalkan ketidakcekapan yang mahal. Cabaran biasa termasuk:
Masa Henti Tidak Berjadual: Component failures in harsh environments lead to production halts, menelan belanja ribuan sejam dalam kehilangan keluaran dan buruh terbiar.
Inconsistent Throughput: Fluctuations in feed material hardness or size cause choke points, preventing the plant from consistently achieving its rated 250300 kapasiti tph.
Kos Operasi yang Tinggi: Excessive energy consumption from inefficient drives and frequent, costly wear part replacements directly impact your costperton metric.
kawal selia & Supply Chain Friction: Sourcing components that are not uniformly RoHS compliant can lead to procurement delays, project specification noncompliance, and potential reputational risk.

Persoalan utama ialah: how do you specify a crushing plant that delivers reliable, rated throughput while controlling total operational expenditure and ensuring modern environmental compliance?

2. GAMBARAN KESELURUHAN PRODUK

Produk ini adalah lengkap, preengineered RoHS Compliant 250300tph Stationary Stone Crushing Plant. It is designed as a turnkey solution for highvolume production of aggregates for road base, konkrit, and asphalt applications.

Aliran Kerja Operasi:
1. Penghancuran utama: Bahan suapan besar (≤750mm) dikurangkan oleh penghancur rahang yang teguh atau impak utama.
2. Sekunder & Penghancuran tertiari: Material is conveyed to cone crushers and/or secondary impactors for further size reduction and shaping.
3. Pemeriksaan & Pengelasan: Vibrating screens separate material into specified product sizes; oversize is recirculated.
4. Pengendalian bahan: A network of RoHScompliant conveyors with energyefficient drives transfers material between stages.
5. Penindasan Debu: Sistem semburan bersepadu mengawal pelepasan zarah di titik pemindahan.

Skop Permohonan: Ideal for granite, batu kapur, basalt, and river gravel processing in quarrying, perlombongan, dan projek pembinaan berskala besar yang memerlukan konsisten, highquality spec aggregates.

Batasan: This plant configuration is designed for stationary or semistationary installation. For projects requiring frequent relocation, a mobile or skidmounted solution should be considered.

3. CIRI TERAS

RoHSCompliant Component Ecosystem | Asas Teknikal: EU Directive 2011/65/EU | Faedah Operasi: Guaranteed supply chain of hazardous substancefree electrical components, pendawaian, and PLC systems | Kesan ROI: Eliminates procurement delays for regulated markets and futureproofs your asset against tightening global environmental standards.

Intelligent LoadSensing Hydraulic System | Asas Teknikal: Variable displacement pumps paired with pressurecompensated valves | Faedah Operasi: Hydraulic power on demand for crusher adjustment and clearing functions reduces parasitic energy loss | Kesan ROI: Data medan menunjukkan sehingga satu 18% reduction in hydraulic system energy consumption compared to fixedflow systems.

Kawalan PLC Bersatu & Monitoring Platform | Asas Teknikal: Centralized Siemens/AllenBradley controller with HMI interface | Faedah Operasi: Your operators can monitor motor loads, suhu yang mengandungi, and production totals from a single station for proactive management | Kesan ROI: Reduces fault diagnosis time by an estimated 30% and enables datadriven maintenance scheduling.

Modular Crusher Cavity & Liner Designs | Asas Teknikal: Interchangeable liner profiles and mantle/bowl designs for jaw and cone crushers | Faedah Operasi: Enables quick reconfiguration of the crushing circuit to adapt to changes in feed material or final product specification | Kesan ROI: Extends wear part life cycle by optimizing crush profiles; increases plant utilization for varied contracts.

HeavyDuty Vibrating Screen with Polyurethane Media | Asas Teknikal: HighGforce exciters coupled with abrasionresistant PU screen panels | Faedah Operasi: Provides consistent screening efficiency with reduced blinding and lower noise generation | Kesan ROI: Longer panel life reduces changeout frequency; improved accuracy minimizes recrush of onspec material.

Centralized Greasing & Sistem Pelincir | Asas Teknikal: Automated singleline progressive system for all major crusher bearings | Faedah Operasi: Ensures correct lubrication intervals without manual intervention at multiple hardtoaccess points | Faedah Operasi: Mengurangkan risiko kegagalan menanggung; documented to extend bearing service life by approximately 25%.

Structural DynamicsOptimized Support Fabrication | Asas Teknikal: FEA (Analisis Unsur Terhingga) designed supports and platforms to mitigate resonant vibration | Faedah Operasi: Reduces structural fatigue stress on conveyors, skrin, and chute work during fullload operation| ROI Impact Lowers longterm structural maintenance costs; minimizes vibrationinduced fastener failures.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (250300tph Loji) | This RoHS Compliant Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Kecekapan tenaga (kWj/tan) | ~0.85 1.0 kWj/tan (dianggarkan) VFDs optional| ≤0.75 kWh/tonne VFDs standard on all major drives| Hingga 15% pengurangan |
| Wear Part Cost Index (Relative) Garis dasar = 100| Index of 100 (Manganese steel standard) Index of ~8590 (Hybrid/alloy options)| Index of ~80 Reka bentuk rongga yang dioptimumkan + optional ceramic composites| Hingga 20% potensi pengurangan |
| Masa Min Antara Kegagalan (MTBF) Electrical Components| Varies widely based on component sourcing.| Increased MTBF Guaranteed RoHS compliance ensures highergrade industrial components| Documented ~40% improvement in component reliability |
| Ketekalan Throughput (% of time at rated capacity)| ~8085% due to feed variation & tersumbat.| ~9092% Intelligent load management & cavity optimization| ~7% increase in operational availability |

5. SPESIFIKASI TEKNIKAL

Kapasiti Direka: 250 300 tan sejam (tph), bergantung pada kekerasan bahan suapan (<200 Mpa recommended) and final product size.
Pilihan Penghancur Utama: Kursus rahang (PE900 × 1200) or HeavyDuty Primary Impact Crusher.
Peringkat Menengah/Tertiari: Combination of MultiCylinder Hydraulic Cone Crushers (mis., HPC315) and/or Secondary Impact Crushers.
Peringkat Saringan: Skrin bergetar tugas berat tripledeck (3YK3072).
Keperluan Kuasa: Jumlah kuasa terpasang lebih kurang 800 950 kw. Requires stable threephase industrial supply.
Spesifikasi Bahan Utama: Semua komponen elektrik (pendawaian, PLCs relays sensors switches etc.) comply with EU RoHS Directive Restriction of Hazardous Substances). Major steel structures utilize S355JR grade steel; wear liners use highmanganese steel or optional ceramic composites.
Anggaran Jejak: ~75m (L) x 45m (W), tertakluk kepada konfigurasi susun atur akhir.
Julat Operasi Persekitaran: Designed for 10°C to +45°C ambient temperature Dust suppression system maintains operation within local particulate emission standards

6. SENARIO APLIKASI

Granite Quarry Expansion Project Challenge A quarry needed to expand output but faced strict new environmental regulations requiring RoHScompliant equipment for the entire site upgrade Their existing plant suffered from low electrical reliability Solution Installation of this RoHS compliant tph stone crushing plant as the new primary production line Results The project met the tender's environmental specification exactly achieving consistent tph output Postinstallation analysis showed a % reduction in electrical component failures compared to the older line

LargeScale Infrastructure Contractor Challenge A contractor securing multiple projects with varying aggregate specifications required flexible highvolume production without constant reinvestment Frequent changeovers were causing significant downtime Solution Implementation of the modular crushing plant featuring quickly reconfigurable crusher cavities liner sets Results The crew can now reconfigure the circuit from producing road base to concrete aggregate in under hours Plant utilization increased by enabling fulfillment of diverse contracts

Aggregate Producer Focused on TCO Total Cost Ownership Challenge Rising energy costs unpredictable wear part expenses were making costperton projections unreliable Management needed predictable operational expenditure Solution Adoption of the complete solution featuring loadsensing hydraulics standard VFDs optimized wear parts Results Achieved a documented kWh tonne saving stabilized monthly consumables spend leading to a predictable costperton model that improved bidding accuracy

7 PERTIMBANGAN KOMERSIL

Peringkat harga peralatan disusun mengikut pilihan konfigurasi teras:

Tier Basic Configuration Includes primary jaw crusher secondary cone crusher tripledeck screen basic conveyors central control panel
Tier Enhanced Configuration Adds tertiary crushing stage VFDs on all major drives upgraded polyurethane screen media automated greasing system
Tier Turnkey Premium Includes full dust suppression enclosure advanced rockbreaker at feed hopper comprehensive spare parts package extended commissioning support

Optional Features Onboard power generation package advanced particle size monitoring system remote telematics connectivity extra set of wear parts
Service Packages Available Annual inspection maintenance contracts operator training programs guaranteed critical parts availability within hours
Financing Options Flexible leasing structures operating lease finance lease available through partnered institutions can be tailored to match project cash flow timelines

8 Soalan Lazim

What does 'RoHS Compliant' mean specifically for this crushing plant It means all electrical electronic components within the plant from motors wiring control cabinets PLCs sensors lighting are manufactured without restricted hazardous substances like lead mercury cadmium This ensures compliance with EU other international markets simplifies disposal recycling

How does this plant handle variations in feed material hardness The combination multi cylinder hydraulic cone crushers allows realtime adjustment CSS Closed Side Setting via the PLC interface This along selectable cavity profiles lets operators tune performance maintain product spec without stopping

What is typical installation commissioning timeline For greenfield site typical timeline weeks from delivery completion civil works This includes days onsite commissioning operator training by factory engineers Timeline varies based site preparedness

Are spare parts readily available given specialized components Yes Core wear parts mantles concaves jaw plates are standardized common models Nonwear electrical components are industrystandard RoHS compliant items ensuring global availability through our network local distributors

Can existing equipment be integrated into this new plant system Yes The control system designed accommodate integration legacy equipment conveyors screens provided their specifications compatible Engineering review required ensure seamless interoperability