1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang meningkat dan masa henti yang tidak menentu menghakis keuntungan kuari anda? Managing a stone quarry crushing plant presents distinct challenges that directly impact your bottom line. Titik kesakitan biasa termasuk:
Masa Henti Berlebihan untuk Penyelenggaraan: Perubahan pelapik yang kerap, kegagalan galas, dan kerosakan yang tidak dijangka menghentikan pengeluaran. Data industri menunjukkan masa henti yang tidak dirancang boleh melebihi kos $10,000 sejam dalam kehilangan output dan buruh.
Penggredan Produk Tidak Konsisten: Turun naik dalam bahan suapan atau prestasi penghancur membawa kepada agregat offspec, mengakibatkan penolakan produk, kos rerushing, dan pelanggan yang tidak berpuas hati.
Penggunaan Tenaga Tinggi: Ruang penghancuran dan pemacu yang tidak cekap menggunakan kuasa yang berlebihan, making energy one of the largest variable costs in your processing circuit.
Degradasi Bahagian Pakai Pantas: Abrasive stone varieties cause accelerated wear on liners, Hammers, dan rahang, leading to high consumable costs and frequent production pauses.
Fleksibiliti Terhad & Skalabiliti: Inflexible plants struggle to adapt to changing market demands for different aggregate sizes or increased throughput.

Is your current solution equipped to minimize these operational risks? The right primary crushing station is not just a purchase; it's a strategic investment in plantwide stability and efficiency.

2. GAMBARAN KESELURUHAN PRODUK

The cornerstone of any efficient operation is a robust primary jaw crusher station. Engineered for the initial reduction of blasted quarry rock (typically from 600900mm down to 150250mm), this equipment forms the critical first stage in your size reduction circuit.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Dump trucks or wheel loaders deposit shot rock into a heavyduty vibrating grizzly feeder (VGFF VGF).
2. PraSkrining & ByPass: The VGF removes natural fines and sub150mm material, directing it to a bypass conveyor to reduce unnecessary crusher load and wear.
3. Penghancuran utama: Oversize material is conveyed into the jaw crusher, di mana rahang tetap dan rahang bergerak menggunakan daya mampatan yang besar untuk memecahkan batu.
4. Pelepasan & Pengangkutan: Bahan hancur dilepaskan ke penghantar produk utama untuk diangkut ke penghancuran sekunder atau penimbunan.

Skop Permohonan & Batasan:
Skop: Sesuai untuk kuari batu keras (granit, basalt, batu perangkap) and abrasive applications. Suited for stationary primary crushing stations.
Batasan: Tidak direka untuk membentuk produk akhir atau penghancuran ultrahalus. Requires competent feed material; sticky or highclay content feed can cause chamber packing without proper prescreening.

3. CIRI TERAS

Ruang Penghancuran Dalam & Sudut nip agresif | Asas Teknikal: Optimized kinematics design | Faedah Operasi: Enables higher throughput capacity and effective breaking of larger feed blocks | Kesan ROI: Meningkatkan tan diproses sejam (Tph), improving asset utilization

Rangka Keluli Fabrikasi Tugas Berat | Asas Teknikal: Analisis Unsur Terhingga (FEA)optimized construction | Faedah Operasi: Menyediakan ketahanan yang luar biasa terhadap beban kejutan daripada bahan yang tidak boleh dihancurkan | Kesan ROI: Mengurangkan risiko kegagalan rangka bencana, memanjangkan hayat operasi seterusnya 20 tahun

Pelarasan Hidraulik & Sistem Penjelasan | Asas Teknikal: Silinder hidraulik bersepadu untuk ketegangan togol dan pembersihan ruang | Faedah Operasi: Allows quick CSS adjustment for product size changes and automatic release of tramp iron | Kesan ROI: Cuts adjustment time by 70% berbanding sistem manual, meminimumkan masa henti

Bolted Bearing Cartridge Design | Asas Teknikal: Modular, preassembled bearing housings | Faedah Operasi: Enables faster replacement of pitman bearings without machining onsite | Kesan ROI: Reduces critical bearing service time from days to hours, significantly boosting availability

Galas Penggelek Sfera Gred Kuari | Asas Teknikal: Oversized bearings with L10 life calculations exceeding 50,000 jam | Faedah Operasi: Handles high radial and axial loads with superior reliability | Kesan ROI: Lowers total cost of ownership by extending service intervals and preventing unplanned stoppages

Replaceable Liners with Multiple Profiles | Asas Teknikal: High manganese steel alloys with optional chrome or ceramic additives | Faedah Operasi: Offers profile choices (mis., corrugated, kuasi) to match rock abrasiveness and desired output shape | Kesan ROI: Optimizes liner lifetocost ratio; data medan menunjukkan sehingga 30% longer life in abrasive granite

Pangkalan Motor Bersepadu & Pengawal Memandu | Technical Basis Unified baseplate design with safetycompliant guarding| Operational Benefit Simplifies installation alignment and ensures operator safety during routine inspections| ROI Impact Reduces installation labor costs by approximately 15% and mitigates safety incident risk

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Penyelesaian Jaw Crusher Kami | Kelebihan (% penambahbaikan) |
|||||
| Ketersediaan Mekanikal | 9092% | 9496% | +4% masa beroperasi |
| Kehidupan Pelapik (Granit Lelas)| 120,000 150,000 tan | 180,000 200,000 tan | +30% jangka hayat |
| Penggunaan tenaga | Garis dasar | Geometri ruang yang dioptimumkan & pemacu |8% kWj setiap tan |
| Masa Penggantian Galas | 2436 jam | 812 jam |67% service duration |
| Kapasiti throughput | Baseline TPH Higher stroke & speed capability +15% TPH in comparable duty |

5. SPESIFIKASI TEKNIKAL

Kapasiti Julat Model: 300 1,800 MT/H (varies by feed material density)
Julat Pembukaan Suapan: 900mm x 600mm up to 1,500mm x 1,200mm
Keperluan kuasa: Motor penghancur utama dari 75 kW sehingga 300 kw (400V/50Hz atau boleh disesuaikan). Complete station includes feeder & pemacu penghantar.
Spesifikasi Bahan: Main frame – S355J2 steel; Liners – Mn18Cr2 / Mn22Cr2; Shaft – forged42CrMo4 steel.
Dimensi Fizikal (Stesen): Typical footprint ranges from ~15m L x ~6m W x ~7m H.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C. Standard pengedap habuk; pakej pemanasan pilihan tersedia.

6. SENARIO APLIKASI

Projek Pembesaran Kuari Granit

Challenge A granite quarry needed to increase primary circuit throughput by25%to feed anew secondary cone crusher line without expanding their blasting schedule
Solution Installation ofa highcapacity jaw crusher station with an aggressive nip angle anda deeper chamber tomaximize tonnage from existing feed size
Results Achieveda28%increasein primary throughput(measured intons per blast pile) andreduced the average product size P80by15%, meningkatkan kecekapan penghancur kon sekunder

Transitioningto More Abrasive Feed Material

Challenge A limestone quarry facing depletion needed tousea new pitwith significantly more chertand quartz inclusions leading tounacceptable wear rates ontheir existing primary crusher
Solution Retrofitteda new jaw crusher featuring bolted bearing cartridges foreasier maintenanceand installed optional hybrid ceramic/manganese liners inthe most critical wear zones
Results Extended liner change intervals from6weeks backto the original8week cycle despite more abrasive feed reducing annual liner costby22%and maintaining availability

7.PERTIMBANGAN KOMERSIL

Equipment pricing is tiered based on size capacity:
Peringkat1(300600Tph): Foundational modelsfor smallto midsize quarries
Peringkat2(6001200Tph): Highperformance modelswith advanced hydraulicsand telemetry standard
Peringkat3(12001800Tph): Heavyduty stationsfor largescale mining operations including integrated automation interfaces

Ciri Pilihan:
Advanced wear monitoring systems Remote vibration sensing packages Automated grease lubrication systems Walkin modules forenclosed maintenance

Pakej Perkhidmatan:
Level1– Parts& Sokongan(standard warranty)
Level2– Scheduled Inspections& Pemantauan Keadaan(includes annual health check)
Level3– Full Maintenance Agreement(covers planned parts laborand24/7 emergency support)

Financing Options Available through partner institutions including operating lease capital leaseor projectbased financing typically structured over37years

8.Soalan Lazim

Q Can this jaw crusher station integrate with our existing PLC control system?
A Yes most models feature standardized communication protocols(Modbus Profibus) allowing integration into existing plant SCADA systems formonitoring key parameters like power drawand CSS

Q What isthe expected impact onour overall plant energy consumption?
A Field data shows that due toefficient drive designand optimized kinematics our solution typically reduces energy useper tonof crushed material by510% depending onthe rock hardness This directly lowers operating costs

Q Adakah alat ganti haus tersedia secara global?
A We maintain regional inventory hubs onthree continents ensuring critical wear parts like linersare available within48hours formost locations minimizing potential downtime

Q What arethe commercial terms formajor spare parts?
A We offer guaranteed pricing contracts forwear part kits which lock inprices fora defined period(usually1224months) providing predictable budgetingforyour maintenance planning

Q How long doesinstallation typically takeand what site preparation isrequired?
A Fora complete station installation requires approximately1014days with our supervised erection team Site preparation requires level compacted ground anda concrete foundation accordingtosupplied engineering drawings delivered prior tomobilization