1. ABERTURA ACIONADA POR PAINPOINT

Are you managing a midtolarge scale aggregate production operation and facing persistent bottlenecks that cap profitability? Para gerentes de fábrica e empreiteiros de engenharia, uma planta de britagem de pedra de 250.300 tph representa um nível de produção crítico onde as ineficiências se traduzem em impacto financeiro significativo. Os desafios comuns incluem:
Taxa de transferência inconsistente: Unplanned downtime from feeder to crusher mismatches or conveyor bottlenecks, losing hundreds of tons per shift.
Altos custos operacionais: Spiking wear part consumption in secondary/tertiary stages and excessive energy use per ton of finished aggregate.
Variação de qualidade do produto: Incapacidade de atender consistentemente a múltiplas especificações de produtos (por exemplo, 3/4" agregar, 1/2" fichas, areia manufaturada) from variable feed material.
Excessive Footprint & Tempo de configuração: Modular plants that require extensive civil works and complex interconnection, delaying commissioning and ROI.

A questão central é: how do you achieve reliable 250300tph output with lower costperton, manutenção simplificada, and the flexibility to adapt to changing project demands?

2. VISÃO GERAL DO PRODUTO

Esta planta estacionária de britagem de pedra de 250.300 tph é uma unidade completa, engineered solution designed for continuous, produção em alto volume de agregados para bases rodoviárias, concreto, e aplicações de asfalto. Está configurado para primário, secundário, and tertiary crushing stages to produce precisely graded end products.

Fluxo de Trabalho Operacional:
1. Redução Primária: Grande rocha de pedreira (até 750 mm) is fed into a primary jaw crusher for initial size reduction.
2. Britagem Secundária & Triagem: A saída é transportada para um britador cônico secundário. Uma tela primária separa o material dimensionado, routing oversize back for further crushing.
3. Modelagem Terciária & Dimensionamento Final: Material requiring additional shaping is processed through a tertiary cone or impact crusher. Final screening decks separate the output into 35 specified product stockpiles.

Escopo de aplicação: Ideal para pedreiras de agregados dedicadas, large infrastructure project support bases, and highdemand commercial concrete operations.
Limitações: This plant configuration requires stable, alimentação de hard rock (granito, basalto, calcário). For very abrasive or highsilica content materials, metalurgia de revestimento específica é recomendada. It is not a portable solution and requires planned foundation work.

3. RECURSOS PRINCIPAIS

Pré-montagem Modular | Base Técnica: Skidmounted major component assemblies | Benefício Operacional: Reduz o tempo de instalação no local em até 40% versus compilações componente por componente | Impacto do ROI: Faster commissioning allows revenue generation to begin weeks earlier.

Design inteligente de câmara de britagem | Base Técnica: Optimized cavity geometry and kinematics | Benefício Operacional: Increases yield of inspec product on first pass by an estimated 1520%, reduzindo a carga recirculante | Impacto do ROI: Directly lowers energy consumption and wear on crushers per ton of final product.

Sistema de automação PLC centralizado | Base Técnica: Controlador lógico programável com IHM touchscreen | Benefício Operacional: Permite o controle de todo o fluxo por um único operador, monitors motor loads, e fornece diagnóstico de falhas | Impacto do ROI: Reduces labor requirements for routine operation and minimizes downtime through predictive alerts.

Alimentador Grizzly Vibratório para Serviço Pesado | Base Técnica: Robust sectionalized grizzly bars & high Gforce vibration | Benefício Operacional: Effectively scalps fines ahead of the primary crusher and ensures consistent, alimentação regulamentada | Impacto do ROI: Protects primary crusher from unnecessary wear caused by fines packing and prevents chokefeeding.

Unified Walkway & Acesso de manutenção | Base Técnica: Integrated platform design around all major service points | Benefício Operacional: Fornece segurança, fácil acesso para inspeções diárias, mudanças de revestimento, and belt maintenance | Impacto do ROI: Cuts scheduled maintenance time significantly improves technician safety compliance.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da indústria para plantas de 250.300 tph | Esta solução vegetal | Vantagem (% melhoria) |
| : | : | : | : |
| Consistência de Tonelagem (Monthly Availability) | 9294% disponibilidade operacional | >96% disponibilidade operacional (alvo de projeto) | +24% disponibilidade |
| Consumo de energia (kWh/tonelada) Varia de acordo com o tipo de rocha. Baseline set at industry average. Industry Average Baseline = X kWh/ton Estimated X 0.88 kWh/ton Estimated reduction of ~12% |
| Custo de desgaste ($/tonelada) Secondary Stage Secondary Crusher Wear Cost Secondary Crusher Wear Cost Focus on chamber design & material flow reduces abrasive wear Estimated reduction of ~1015% |
| Tempo de comissionamento no local (Semanas) Componentbycomponent build Modular skid assembly Field data shows reduction of ~3040% |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade projetada: 250 300 toneladas métricas por hora (275 330 TPH dos EUA), depende da dureza do material de alimentação e da distribuição de tamanho.
Triturador Primário: Modelo de britador de mandíbula [por exemplo, JC5460], Feed Opening suitable for up to 750mm rock.
Triturador Secundário: Modelo de britador de cone [por exemplo, MC350], with hydraulic adjustment and clearing.
Triturador Terciário: Cone or Vertical Shaft Impact (TODOS) Modelo Triturador [por exemplo, TC260 or VSI2800] for shaping/fine production.
Unidades de triagem: Multideck vibrating screens (tipicamente 23 unidades), sizes tailored to final product specifications.
Requisitos de energia: Potência total instalada aproximadamente 800 1000 kW. Requires dedicated highvoltage connection as per local grid.
Principais especificações de materiais: Estrutura do quadro principal; Heavyduty steel plate. Conveyor idlers; CEMA C/D rated bearings. Screen meshes; Hightensile wire or polyurethane panels.
Pegada Aproximada (C x L): ~85m x 45m (280' x 150'), sujeito à configuração final do layout.
Faixa operacional ambiental: Designed for 20°C to +45°C ambient temperature with appropriate lubrication systems.

6. CENÁRIOS DE APLICAÇÃO

[Regional Granite Quarry] Desafio: An established quarry needed to upgrade from a 200tph system to meet new highway contract demands without expanding its operational footprint or significantly increasing crew size.

[Large Infrastructure Project Dam Construction] Desafio: A remote dam construction site required consistent production of multiple aggregate specifications (from riprap to fine aggregates) with limited technical personnel available onsite.

[Commercial Asphalt Producer] Desafio: A producer aimed to increase yield of highvalue manufactured sand from their limestone feed while maintaining strict gradation control for asphalt mixes.

[Solução]: Implementation of this modulardesigned plant allowed the existing footprint to be utilized efficiently. The centralized PLC system enabled management of the higher throughput with the same operator team.

[Solução]: A ruggedized version was supplied with preassembled modules. The design prioritized reliability over ultimate flexibility.

[Solução]: Integration included a tertiary stage VSI crusher. The automation system was programmed with specific recipes for different sand products.

[Resultados]: Atingiu uma produção sustentada de 280tph. Plant availability increased from under 95%, meeting supply obligations on schedule without added labor costs.

[Resultados]: Plant commissioned in months typical timeline). Achieved reliable >260tph output in harsh conditions with minimal specialist intervention required.

[Resultados]: Increased saleable sand yield by >22%. A consistência do produto melhorou dramaticamente. Allowed entry into new markets requiring precise filler material.

7. CONSIDERAÇÕES COMERCIAIS

Our solutions are offered in clear pricing tiers based on core configuration:

Tier A – Base Plant Configuration includes primary jaw crusher secondary cone crushers primary screen core conveyors central control cabin
Tier B – Enhanced Configuration adds tertiary crushing stage additional final screening decks dust suppression system
Tier C – Turnkey Premium Configuration includes all above plus full electrical switchgear package advanced automation with production reporting preassembly services

Optional features include automated lubrication systems metal detection tramp iron relief systems sound enclosures

Service packages are available separately ranging from basic commissioning supervision through comprehensive multiyear maintenance agreements including parts kits

Financing options can be discussed including equipment leasing structures tailored for capital expenditure cycles typical in the aggregates industry

8.Perguntas frequentes

Q1 Is this plant compatible with our existing primary feeding system or stacker conveyor?
A1 Yes provided your existing feeder or stacker can handle the required steadystate tonnage up to Our engineering team can review interface points like hopper dimensions discharge heights transfer chute designs

Q2 What is the expected operational impact during liner changes on the secondary cone crushers?
A2 With standard tooling field data indicates a trained twoperson crew can complete mantle concave replacement in Downtime can be further reduced with optional hydraulic assist kits

Q3 How does this plant manage variations in feed material hardness which we commonly experience?
A3 The PLC system monitors motor loads adjusting feeder rates accordingly Secondary tertiary crushers feature hydraulic adjustment allowing closedside setting changes under load within limits adapting quickly without stopping production

Q4 Are spare parts packages included in the initial purchase price?
A4 No spare parts are quoted separately We recommend an initial wear parts kit based on projected This ensures critical components are on hand minimizing potential downtime due to logistics delays

Q5 What level of operator training is provided?
A5 Comprehensive training is included covering normal operation startup shutdown sequences basic troubleshooting safety procedures Training occurs during commissioning both classroom style handson at controls Typically spans

Q6 Can this plant be reconfigured later if our product focus shifts e.g more emphasis on manufactured sand?
A6 The modular design allows reconfiguration Adding a VSI crusher as an additional tertiary stage or modifying screen decks are common future modifications Civil foundation planning initially considers such potential expansions

Q7 What are standard payment terms delivery lead times?
A7 Standard commercial terms involve progress payments tied milestones like order confirmation completion factory testing shipment Lead times typically range order confirmation depending current manufacturing schedule complexity chosen options