1. PAINPOINT DRIVEN OPENING

Managing an iron ore crushing circuit presents distinct, highcost challenges. Are you facing persistent bottlenecks that limit your plant’s rated throughput? Is unscheduled downtime for liner changes and component wear eroding your production schedule and maintenance budget? Do you struggle with inconsistent product sizing, leading to downstream processing inefficiencies in grinding or beneficiation? Furthermore, are rising energy costs per ton of processed material directly impacting your operational margins? These issues translate into quantifiable losses: hours of lost production, excessive spare parts inventories, and suboptimal resource yield.

The central question for plant managers is this: how can you achieve reliable, hightonnage reduction of abrasive iron ore while controlling capital and operational expenditure? The solution lies in specifying a purposeengineered private label iron ore crushing plant.

2. PRODUCT OVERVIEW

This product is a complete, modular crushing system engineered for primary and secondary reduction of magnetite, hematite, and other ironbearing ores. It is supplied as a private label solution, allowing for branding alignment while leveraging proven, heavyduty componentry.

Operational Workflow:
1. Primary Dump & Grizzly: Runofmine ore is dumped onto a rugged grizzly feeder, scalping out fine material to bypass the primary crusher, enhancing overall efficiency.
2. Primary Jaw Crushing: A heavyduty jaw crusher performs initial size reduction, delivering a consistent feed to the secondary stage.
3. Secondary Cone Crushing: The heart of the system, a highcapacity cone crusher—configured for coarse or mediumfine output—provides the final cubical product sizing critical for downstream processing.
4. Screening & ClosedCircuit Control: Sized material is screened; oversize is recirculated back to the cone crusher in a closedloop system ensuring precise final product specification.

Application Scope & Limitations:
Scope: Ideal for greenfield installations or expansion projects requiring 500 to 2,500+ TPH capacity. Suited for processing hard, abrasive iron ores with compressive strengths up to 350 MPa.
Limitations: Not designed as a tertiary or quaternary stage for ultrafine grinding. Feed size must conform to crusher opening specifications. Optimal performance requires consistent feed gradation and controlled moisture content to prevent chamber packing.

3. CORE FEATURES

HeavyDuty Liner Geometry | Technical Basis: Computermodeled cavity profiles and highchrome white iron metallurgy | Operational Benefit: Extended wear life by 3050% over standard manganese steel in abrasive service | ROI Impact: Reduces liner change frequency and inventory costs, increasing crusher availability.

Advanced Chamber Clearing System | Technical Basis: Hydraulic or gaspowered tramp release and clearing automation | Operational Benefit: Recovers from stall conditions in under 60 seconds without manual intervention | ROI Impact: Prevents cascading downtime from uncrushable material, protecting downstream conveyor systems.

Centralized Greasing & PLC Control | Technical Basis: Automated lubrication intervals tied to bearing temperature and operating hours | Operational Benefit: Ensures optimal bearing health and eliminates manual greasing errors | ROI Impact: Extends major bearing service life by up to 40%, reducing risk of catastrophic failure.

Modular Skid Design | Technical Basis: Preassembled structural steel skids with integrated walkways and maintenance platforms | Operational Benefit: Reduces onsite civil works and installation time by an estimated 40% | ROI Impact: Lowers total installed cost (TIC) and accelerates timetoproduction.

Variable Frequency Drive (VFD) Compatibility | Technical Basis: Crusher motor integration with plantwide process control systems | Operational Benefit: Allows realtime adjustment of crusher speed/throw to match feed conditions for optimal power draw and product shape | ROI Impact: Achieves energy savings of 1015% under variable load conditions versus fixedspeed operation.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (AggregateFocused Plant) | Private Label Iron Ore Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Wear Life (Abrasive Ore) | ~450,000 tons per set (Manganese) | ~650,000 tons per set (Special Alloy) | +44% |
| System Availability (Scheduled) | ~92% (incl. liner changes) | ~95% (incl. liner changes) | +3 Percentage Points |
| Power Consumption per Ton Processed| Baseline (100%)| Optimized chamber & drive = ~90% of baseline |10% |
| Installation & Commissioning Time| 810 weeks on site| 56 weeks on site (modular)| 30% |
| Product Fines (10mm) Control| Typically 1822% of output| Chamber optimization yields 1518% of output| 20% reduction in unwanted fines |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 500 TPH to over 2,500 TPH nominal throughput of taconite ore.
Power Requirements: Primary Crusher: 150400 kW; Secondary Crusher: 250600 kW; Total System Feeders/Conveyors/Screens: Additional 300800 kW dependent on configuration.
Material Specifications: Primary wear liners in premium manganese steel; Secondary chamber liners in highchrome white iron (27% Cr). Structural steel is Grade S355JR with abrasionresistant plate in highwear zones.
Physical Dimensions (Typical Skid): Secondary crushing module approx. L12m x W6m x H7m. Full plant footprint varies with configuration.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C with optional heating/cooling packages. Dust suppression system integrated as standard.

6. APPLICATION SCENARIOS

Greenfield Magnetite Concentrator Expansion

Challenge:
A major mining operator needed to expand concentrator throughput but was constrained by existing primary crushing capacity producing inconsistent feed size for new SAG mills.
Solution:
Implementation of a turnkey private label iron ore crushing plant as a parallel primary/secondary circuit specifically calibrated for their magnetite ore characteristics.
Results:
Achieved a sustained throughput increase of 1,800 TPH at a consistent 25mm product size. Mill feed stability improved grinding circuit efficiency by an estimated 8%, contributing directly to higher concentrate output.

Lifecycle Replacement in Hematite Operation

Challenge:
An aging fleet of disparate crushers led to high maintenance costs (~20% of annual OPEX), poor availability (94%.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Offered across three standardized capacity tiers—Medium Duty (1,800 TPH)—with corresponding component specifications.
Optional Features: Upgrades include advanced predictive monitoring sensors (vibration/temperature), automated wear measurement systems, hybrid diesel/electric power modules for remote sites,
and enhanced dust encapsulation packages.
Service Packages: Tiered annual support agreements are available covering scheduled maintenance inspections,
predictive analytics review,
and priority parts provisioning with guaranteed dispatch times.
Financing Options: Flexible capital expenditure solutions can be structured including equipment leasing models,
project financing linked to production milestones,
or traditional purchase agreements.

8.FAQ

Q1:
Are these private label plants compatible with our existing conveying infrastructure?
A1:
Yes.The modular design allows engineering interfaces
(discharge heights,
feed chute orientations)
to be customized during the design phase
to integrate with your current stockpile conveyors
or downstream process feed points.Field surveys are conducted
to ensure dimensional compatibility prior
to fabrication

Q2:
What is the expected operational impact during commissioning?
A2:
Our phased commissioning protocol minimizes disruption.Crushing modules are pretested at our facility.Onsite commissioning typically requires two weeks
of planned integration downtime followed by one week
of rampup under supervision until design capacity is met

Q3:
How does the pricing compare
to sourcing major OEM equipment directly?
A3:
The private label model typically offers capital cost savings between fifteen percent without compromising critical component quality.We achieve this through optimized global supply chain logistics
for structural components while utilizing tierone suppliers
for all mechanical drive
and wear parts

Q4:
What are the lead times from order placement
to delivery?
A4:
For standard capacity configurations lead time ranges from twentysix weeks depending on current manufacturing schedule.Complex customizations may extend this timeline which will be defined during project scoping

Q5:
Is training provided for our operations
and maintenance teams?
A5:
Comprehensive training is included covering safe operation routine maintenance procedures troubleshooting guides specific documentation review conducted both at your site during commissioning

Q6:
What warranty terms apply?
A6:
The complete structure carries standard warranty.All major mechanical components including crusher main frames shafts bearings motors carry manufacturer warranties which we manage on your behalf providing singlepoint support

Q7:
Can this plant handle variations in ore hardness within our deposit?
A7：
The hydraulic adjustment systems on both jaw cone crushers allow operators adjust closed side settings compensate variations hardness maintain consistent product size PLC control system can automate adjustments based power draw maintaining optimal performance across different ore zones