1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing a midtolarge scale aggregate operation and facing the constant pressure to balance highvolume output with operational stability? Cabaran loji penghancur batu 250300tph adalah penting. Masa henti yang tidak dirancang akibat kegagalan peralatan boleh menelan belanja ribuan sejam dalam kehilangan pengeluaran dan buruh terbiar. Inconsistent feed material leads to fluctuating final product gradation, causing rejections and compromising contract compliance. Kos tenaga yang meningkat secara langsung menghakis margin keuntungan pada setiap tan yang dihasilkan. Tambahan pula, meeting stringent environmental regulations on dust and noise adds complexity and capital expense. Adakah isu ini memberi kesan kepada pendapatan anda? Bagaimana anda mencapai kebolehpercayaan, hightonnage production while controlling operational costs and ensuring plant longevity? The solution lies in a fundamentally robust and intelligently engineered crushing plant design.

2. GAMBARAN KESELURUHAN PRODUK

This datasheet details a complete stationary 250300tph kilang penghancur batu engineered for granite, basalt, batu kapur, and other hard rock applications. It is a multistage processing system designed for continuous, highvolume production of highquality aggregates (05mm, 510mm, 1020mm, 2031.5mm).

Aliran Kerja Operasi:
1. Penghancuran utama: Dump trucks feed material into a largecapacity vibrating grizzly feeder which removes fines before directing oversize to a heavyduty jaw crusher for initial size reduction.
2. Sekunder & Penghancuran tertiari: The primary crushed material is conveyed to a cone crusher for secondary reduction. A subsequent cone crusher or impact crusher (depending on material abrasiveness and product shape requirements) performs tertiary crushing.
3. Pemeriksaan & Pengelasan: Material is routed through multipledeck vibrating screens to precisely separate it into specified product sizes.
4. Pengendalian bahan & Stok: Onspec aggregates are conveyed to designated stockpiles via radial stackers or fixed conveyors, while oversize material is recirculated back to the appropriate crusher.

Skop Permohonan: Sesuai untuk operasi kuari besar, sokongan projek infrastruktur utama (lebuh raya, Keretapi), and commercial concrete/asphalt plant feed. Batasan: Not suitable for portable or skidmounted applications; requires stable foundation and substantial upfront civil works.

3. CIRI TERAS

Sistem Kawalan Suapan Pintar | Asas Teknikal: Pemacu Frekuensi Boleh Ubah (VFD) on feeder with level sensors | Faedah Operasi: Maintains optimal chokefeed condition for crushers, preventing empty running and cavity flooding | Kesan ROI: Hingga 15% reduction in energy consumption per ton and ~10% increase in liner life.

Centralized Dust Suppression Envelope | Asas Teknikal: Titik pemindahan berkapsul dengan meriam kabus yang diletakkan secara strategik & bag filters | Faedah Operasi: Contains dust at source across entire flow path, ensuring compliance and improving site visibility/worker health | Kesan ROI: Mitigates regulatory fines and reduces cleanup labor by an estimated 30%.

Reka Bentuk Ruang Penghancuran Kecekapan Tinggi | Asas Teknikal: Laminated crushing principle with optimized kinematics in jaw and cone crushers | Faedah Operasi: Generates more interparticle crushing for improved product shape (higher cubicity) and increased yield of premium fractions | Kesan ROI: Higher market value for crushed products and reduced waste.

Logik Proses Automatik Berasaskan PLC | Asas Teknikal: Programmable Logic Controller with HMI touchscreen monitoring crusher load, kelajuan penghantar, and screen efficiency | Faedah Operasi: Allows singleoperator oversight of entire plant flow; automatic adjustments prevent overloads and blockages | Kesan ROI: Reduces operational staffing requirements by up to 2 FTE per shift while increasing system availability.

Reka Bentuk Akses Penyelenggaraan Modular | Asas Teknikal: Pelarasan hidraulik & setting release systems on crushers; walkin platforms around all major components | Faedah Operasi: Enables faster liner changes, routine inspections, and component replacement with standard tools | Kesan ROI: Mengurangkan masa henti penyelenggaraan yang dirancang sehingga 40%, secara langsung meningkatkan jam pengeluaran tahunan.

HeavyDuty Conveyor Specification | Asas Teknikal: CEMA Class IV idlers with impact beds at loading zones; sambatan tali pinggang tervulkan | Faedah Operasi: Eliminates premature belt wear at transfer points, drastically reducing belt failure risk—a leading cause of unplanned stoppage | Kesan ROI: Memanjangkan masa min antara kegagalan (MTBF) for conveying system by over 50%.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (250300tph Loji) | This Sustainable Stone Crushing Plant Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Overall System Availability | ~85% 88% (Seasonal) |> 92% (Sasaran Tahunan) |> +5% ke +8% |
| Penggunaan Tenaga setiap Tan Hancur| ~1.8 2.1 kWj/t |> 1.6 1.7 kWj/t |> ~10% Reduction |
| Jumlah Kos Pemilikan (5Unjuran Tahun)| Garis dasar |> 1520% Lebih rendah |> Direct Cost Savings |
| Bentuk produk (% Cubical Content)| Varies Widely (~6575%) |> Konsisten > 78% |> Higher Premium Product Yield |
| Noise Emission at Property Line| Selalunya >75 db(A) |> Terkawal < 70 db(A) |> Easier Permitting & Hubungan Masyarakat |

_Based on field data from comparable installations using similar granite feed material._

5. SPESIFIKASI TEKNIKAL

Kapasiti Throughput Direka: 250 300 Ton metrik sejam (tph), bergantung pada kekerasan bahan suapan (<180 MPa disyorkan), Pengagihan saiz (<750mm), dan penggredan produk yang diperlukan.
Jumlah Kuasa Bersambung: Kira -kira 550 650 kw.
Spesifikasi Bahan Utama:
Saiz Suapan Penghancur Utama Maks.: ≤750mm
Saiz Produk Akhir: Configurable from 05mm sand up to 31.5mm aggregate.
Conveyor Belt Width/Speed: Main conveyors typically B1000mm width @1.6m/s.
Jejak Fizikal (lebih kurang): Length ~120m x Width ~65m (excluding stockpile areas). Requires detailed civil foundation engineering.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C dengan sistem pelinciran yang sesuai; standard dust suppression rated for conditions up to 85% kelembapan relatif.

6. SENARIO APLIKASI

Large Quarry Expansion Project

Cabaran: A regional quarry needed to increase output from 200tph to over 280tph reliably to fulfill a new highway contract but faced space constraints and strict new county noise ordinances.
Penyelesaian: Implementation of this compactly designed multistage stone crushing plant featuring soundinsulated enclosures around key equipment like the secondary/tertiary crushers.
Keputusan: Achieved consistent throughput of ≥290tph while passing compliance noise audits (<70dB at site boundary). The automated control system allowed management of the increased throughput without adding shift personnel.

Integrated Concrete Producer

Cabaran: A vertically integrated concrete company operating its own limestone quarry experienced high maintenance costs from abrasive wear on tertiary stage equipment and inconsistent sand yield affecting mix designs.
Penyelesaian: Installation of this plant configuration featuring a tertiary cone crusher specifically selected for abrasive rock with a specialized chamber profile.
Keputusan: Tertiary crusher manganese liner life increased by approximately two weeks per set under identical conditions due to optimized feed from preceding stages combined with chamber design.The consistent gradation curve improved sand yield stability by ±3%, leading directly to more predictable concrete batch quality.

7.PERTIMBANGAN KOMERSIL

A sustainable stone crushing plant represents a significant capital investment designed for longterm returns.

Peringkat Harga Peralatan:
Base Configuration includes primary jaw crusher feeder station secondary cone tertiary impactor basic screening structure conveyors electrical control panel
Enhanced Configuration adds automated grease systems centralized lubrication advanced PLC automation package upgraded dust suppression bag filter units
Turnkey Premium Configuration includes full civil works design support erection commissioning supervision training extended commissioning period

Optional Features include metal detection tramp iron relief systems automatic sampler units remote monitoring telematics packages water recycling systems

Service Packages are offered as annual preventative maintenance contracts including scheduled inspections parts discounts priority technical support

Financing Options available through partner institutions include traditional equipment leasing longterm loans or powerbythehour style performancebased agreements where service costs are bundled

Soalan Lazim

What type of electrical supply is required?
The complete plant typically requires a mediumvoltage connection (~10kV) feeding into a dedicated transformer substation due to the total connected load (~550650kW). Detailed power requirements are provided during the project engineering phase.

How does this setup handle wet or sticky feed material?
The vibrating grizzly feeder deck can be equipped with heating elements or special liners We also recommend screen deck heating systems as an option These features prevent material buildup ensuring consistent flow during cold or damp conditions

What is the expected timeframe from order placement to commissioning?
For a standard configuration lead time is typically months following detailed engineering For turnkey projects including civil works total project duration generally ranges from months subject to sitespecific conditions

Adakah alat ganti sedia ada?
Yes Critical wear parts like mantles concaves jaw plates are standardized items held in regional inventory Standard mechanical electrical components use globally available bearings seals motors drives minimizing procurement delays

Can this plant be reconfigured later if my product requirements change?
Yes The modular design allows for future modifications such as adding an extra screen deck integrating a different tertiary crusher type or rerouting conveyors Engineering support is provided for such upgrade projects