1. PEMBUKAAN PAINPOINT DRIVEN

Managing an iron ore crushing circuit is a highstakes operation where efficiency directly defines profitability. Adakah anda menghadapi cabaran berterusan ini?
Masa Henti Tidak Berjadual: Unplanned stoppages due to tramp metal, uncrushable material, or component failure can cost over $10,000 sejam dalam kehilangan pengeluaran dan buruh.
Penggredan Produk Tidak Konsisten: Turun naik dalam saiz suapan atau kekerasan membawa kepada produk offspec, causing bottlenecks in downstream grinding and processing, reducing overall plant yield.
Kos Penyelenggaraan Tinggi & Pakai: The abrasive nature of iron ore results in rapid wear of liners, Bar Blow, dan bahan habis pakai lain, driving up operational expenditure and requiring frequent, laborintensive changeouts.
Ketidakcekapan Tenaga: Older or improperly configured crushing stages consume excessive power per ton of material processed, a significant and growing lineitem cost.
Ketidakfleksibelan kepada Variasi Suapan: Fixedspeed crushers struggle to maintain optimal performance when ore characteristics change from one pit zone to another.

How can you achieve a more predictable tonnage cost, reduce operational risk, and ensure your primary crushing stage is an asset rather than a bottleneck?

2. GAMBARAN KESELURUHAN PRODUK: WHITE LABEL IRON ORE CRUSHING PLANT

Our solution is a configurable, white label primary and secondary crushing plant engineered specifically for hard, abrasive iron ores (Hematite, Magnetite). It is designed as a modular system for rapid deployment and integration into new or existing mineral processing circuits.

Aliran Kerja Operasi:
1. Primary Dump/Fee: ROM ore is fed via haul truck or loader into a rugged grizzly feeder, which scalps out fine material and directs oversize to the primary crusher.
2. Penghancuran utama: A heavyduty jaw crusher reduces the ore to a nominal 150200mm product.
3. Menghancurkan sekunder & Pemeriksaan: The primary crushed material is conveyed to a secondary cone crusher for further reduction. A closedcircuit screen ensures precise final product sizing before transfer to the next processing stage.

Skop Permohonan & Batasan:
Skop: Ideal for greenfield sites, plant expansion projects, or replacement of aging fixed infrastructure. Suitable for production capacities from 500 ke 2,500+ Tph.
Batasan: Not designed as a tertiary or fine grinding solution. Maximum feed size is limited by primary crusher opening. Plant requires stable, prepared ground for installation.

3. CIRI TERAS

Ruang Penghancuran Adaptif | Asas Teknikal: Pelarasan CSS Hydroset & automated control system | Faedah Operasi: Operators can remotely adjust the closedside setting (CSS) in minutes to compensate for feed changes or optimize product size without stopping the crusher. | Kesan ROI: Maintains target throughput and gradation, preventing downstream bottlenecks; dianggarkan 58% peningkatan hasil.

Sistem Perlindungan Logam Tramp | Asas Teknikal: Hydraulic overload relief cylinders with automatic reset | Faedah Operasi: Instant pressure release protects crusher components from catastrophic damage caused by uncrushable steel or digger teeth. | Kesan ROI: Eliminates risk of major mechanical failure and associated repair costs (often exceeding $50k) and extended downtime.

AbrasionResistant Material Package | Asas Teknikal: Premium manganese steel liners with optimized cavity profiles | Faedah Operasi: Liners withstand extreme abrasion from silicarich iron ore, significantly extending service life between changeouts. | Kesan ROI: Reduces liner consumption costs by 1525% and lowers maintenance manhours per ton crushed.

Direct Drive Crusher Technology | Asas Teknikal: Eliminates Vbelts and sheaves; couples motor directly to crusher | Faedah Operasi: Improves power transmission efficiency (hingga 99%), mengurangkan titik penyelenggaraan, and allows for variable speed control for process optimization. | Kesan ROI: Mengurangkan penggunaan tenaga lebih kurang 812% compared to traditional Vbelt driven systems.

Centralized Greasing & Sistem Pelincir | Asas Teknikal: Automated singlepoint lubrication with monitoring sensors | Faedah Operasi: Memastikan galas kritikal menerima pelinciran yang konsisten tanpa campur tangan manual, menghalang kegagalan dryrun. | Kesan ROI: Memanjangkan hayat galas sehingga 40%, reducing spare parts inventory costs and unplanned stops.

Laluan Pejalan Kaki Modular & Platform Akses | Asas Teknikal: Prefabricated bolttogether safety platforms around all service points | Faedah Operasi: Menyediakan selamat, compliant access for daily inspections and routine maintenance tasks such as liner changes. | Kesan ROI: Reduces safety incident risk and cuts planned maintenance time by up to 30%, meningkatkan ketersediaan tumbuhan.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Fixed Speed/Manual) | White Label Iron Ore Crushing Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Adanya (Masa aktif) | 8590% (terancang & perhentian yang tidak dirancang) | 9396% (systemprotected operation) | +7% Penambahbaikan |
| Penggunaan kuasa (kWj/t)| Pembolehubah; selalunya tidak cekap pada beban separa| Dioptimumkan melalui pemacu terus & variable speed control| Hingga 12% Pengurangan |
| Kehidupan Pelapik (Juta Tan)| Sangat berubah -ubah; frequent changeouts| Extended via material science & reka bentuk ruang| +20% Average Increase|
| Konsisten Penggredan Produk| Can fluctuate ±15% with feed variation| Maintained within ±5% via adaptive controls| +67% Lebih Konsisten|
| Masa Min Antara Kegagalan (MTBF)| Lower due to tramp metal damage risk| Significantly higher with integrated protection| Data shows +35% Penambahbaikan|

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 500 TPH kepada 2,500 TPH nominal throughput of iron ore (S.G. ~2.6 t/m³).
Penghancur utama: Heavyduty jaw crusher with feed openings up to 1,500mm x 1,200mm.
Penghancur sekunder: Highcapacity cone crusher with multiple cavity options.
Keperluan kuasa: Jumlah kuasa terpasang biasanya antara 500 kw 1,200 kW bergantung pada konfigurasi; voltage customizable (mis., 6.6 kV).
Spesifikasi Bahan Utama: Primary frame constructed from hightensile steel plate; pelapik dalam keluli mangan premium (1822%); critical wear areas lined with AR400 steel plate.
Dimensi Fizikal (Modular): Modules designed for standard shipping container dimensions; overall footprint optimized per customer layout.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +50°C; sistem penindasan habuk dimasukkan sebagai standard; electrical components rated for appropriate ingress protection.

6. SENARIO APLIKASI

Greenfield Magnetite Project

Cabaran: A new mining operation required a scalable crushing solution with minimal onsite construction time due to remote location constraints. Consistent 32mm feed for downstream grinding was critical.
Penyelesaian: Implementation of a modular white label iron ore crushing plant with primary jaw and secondary cone crushers in closed circuit with a sizing screen.
Keputusan: Plant commissioned in 60% less time vs traditional build. Achieved steadystate production of 800 TPH meeting target spec (>95% berlalu), enabling onschedule rampup of the concentrator.

Aging Plant Retrofit

Cabaran: An existing hematite processing facility suffered from low throughput (<600 Tph) and excessive downtime in its primary section due to constant liner wear failures on old equipment.
Penyelesaian: Replacement of the legacy primary gyratory with our white label jaw crushing module as a dropin solution within the existing structure footprint.
Keputusan: Daya tampung meningkat lebih 25%. Liner changeout intervals extended from every ~800k tons to over 1 million tons reducing annual maintenance costs by an estimated $120k USD while boosting overall plant availability.

7 PERTIMBANGAN KOMERSIL

Our white label model provides significant commercial flexibility versus branded OEM solutions:

Peringkat Harga:
Konfigurasi Pangkalan: Termasuk modul penghancuran teras (feeder/primary/secondary), walkways/platforms ladders , penindasan habuk asas ,and motor starters .
Konfigurasi Dioptimumkan: Adds variable frequency drives , sistem pelinciran automatik , advanced tramp metal protection ,and PLCbased control panel .
Konfigurasi Turnkey: Full EPC scope including structural supports conveyors electrical substation integration commissioning spares package .

Ciri Pilihan: Onboard weighing instrumentation advanced rock level sensors remote monitoring connectivity packages custom paint schemes .

Pakej Perkhidmatan Tersedia:
1 Annual inspection parts discount program
3 /5year comprehensive service agreements including planned maintenance wear part supply technical support

Pilihan Pembiayaan:
Equipment leasing capital loan facilitation through partner institutions project financing support available

8 Soalan Lazim

Q What level of site preparation is required before delivery?
A The plant modules require prepared concrete foundations equivalent specifications will be provided during engineering Our team can supervise installation

Q How does this system integrate with my existing SAG/Ball mill feed conveyor?
A Our engineering team will design the discharge conveyor interface hopper ensure seamless integration into your current downstream process flow

Q Are spare parts readily available given it's a white label product?
A Yes All critical wearing parts bearings seals are standardized industrial components held global stock Major castings are sourced single certified foundry ensuring consistent supply lead times

S Apakah latihan yang diberikan kepada kakitangan penyelenggaraan operasi kami?
A We provide comprehensive onsite training covering normal operation troubleshooting routine maintenance procedures Detailed manuals schematic diagrams included

Q Can this plant handle lateritic ores sticky moisture content?
A While designed primarily hard abrasive ores we can configure specific options such as impact crushers secondary stage specialized feeder designs manage higher moisture mitigate clogging Discuss your specific feedstock during consultation

Q What typical delivery lead time after order confirmation?
A For standard configurations lead time ranges months depending final specification complexity Current project schedule will be confirmed upon quotation

Q Is performance guarantee offered?
A Yes We provide written performance guarantee covering rated throughput final product PSD specifications based agreed test protocol post commissioning