1. ABERTURA ACIONADA POR PAINPOINT

Você está gerenciando uma operação de produção de agregados de médio a grande porte e enfrentando gargalos consistentes em seu circuito primário de britagem?? Os desafios de uma planta de britagem de pedra de 250.300 tph são significativos: unpredictable feed size variations causing crusher stalls, excessive wear part costs from nonoptimized crushing chambers, and unplanned downtime for liner changes that can cost thousands per hour in lost production. Além disso, inconsistent final product gradation leads to rejected loads and wasted material. Are you questioning how to achieve reliable throughput at the upper end of this capacity range without sacrificing particle shape? Is balancing high uptime with manageable operational expense a constant struggle? A solução não está apenas nos equipamentos, but in a system engineered for this specific output target.

2. VISÃO GERAL DO PRODUTO

Esta planta estacionária de britagem de pedra de 250.300 tph é uma unidade completa, hardrock processing solution designed for granite, basalto, calcário, e outros agregados. It is engineered as a threestage crushing and screening system for consistent production of up to 7 final product specifications.

Fluxo de Trabalho Operacional:
1. Britagem Primária: A robust jaw crusher reduces blasted rock from large feed (tipicamente <750milímetros) para um tamanho gerenciável para processamento secundário.
2. Secundário & Britagem Terciária: A cone crusher (and optionally an additional tertiary crusher or impactor) reduz ainda mais o material, focusing on particle shape and size control.
3. Triagem & Classificação: Multiple vibrating screens accurately separate crushed material into specified product sizes, com material de tamanho grande recirculado para redução adicional.

Escopo de aplicação: Ideal for quarry primary operations, large infrastructure project supply (autoestrada, trilho), e pátios comerciais de fornecimento agregado que exigem alto volume, specificationgrade materials.
Limitações: This is a stationary plant configuration requiring foundational work and utility connections. For fully mobile operations within this capacity range, a different system design is recommended.

3. RECURSOS PRINCIPAIS

Câmara de britagem adaptativa | Base Técnica: Hydraulic CSS adjustment & proteção contra sobrecarga | Benefício Operacional: Operators can adjust product size or clear blockages remotely in minutes without stopping feed | Impacto do ROI: Reduz o tempo de inatividade para ajustes em até 80% em comparação com sistemas de calços manuais.

Intelligent Feed Control | Base Técnica: Unidade de frequência variável (VFD) on feeder conveyors linked to crusher motor load | Benefício Operacional: Automatically regulates feed rate to prevent crusher overload and choking, optimizing throughput | Impacto do ROI: Maximizes capacity utilization, protects drive components from damage, reducing repair costs.

MultiStage Screening Efficiency | Base Técnica: Dedicated screen decks for closedcircuit recirculation and final product separation | Benefício Operacional: Ensures precise cut points and reduces crusher load by removing sized product early in the process | Impacto do ROI: Lowers wear part consumption in crushers and increases total system output by 1525%.

Lubrificação Centralizada & Monitoramento | Base Técnica: Automated lubrication system with central control panel displaying bearing temperatures and pressure | Benefício Operacional: Ensures critical wear points receive consistent lubrication, extending bearing life and preventing failures | Impacto do ROI: Cuts manual lubrication labor by 50% and prevents costly bearing seizurerelated downtime.

HighAbrasion Material Handling | Base Técnica: AR400 steel liners at transfer points, impact beds on conveyor load zones | Benefício Operacional: Protects structural components from wear caused by continuous hightonnage flow of abrasive stone | Impacto do ROI: Extends structural lifecycle of chutes and conveyors, deferring major replacement costs for years.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da indústria para plantas de 250.300 tph | Esta solução de 250.300 tph | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade geral da planta | ~85% (incluindo manutenção programada)| >92% (incluindo manutenção programada)| +8% |
| Custo de desgaste por tonelada (Rock pesado) | $0.45 $0.60/tonelada processada| $0.35 $0.48/tonelada processada| Até 22% |
| Formato do produto (Cubicidade) Index | Média. ratio of 75% conteúdo cúbico| Média. ratio of 82% conteúdo cúbico| +9% |
| Consumo de energia por tonelada | Estimado em 1.8 2.1 kWh/tonelada| Otimizado em 1.65 1.9 kWh/tonelada| Até 12% |
Based on field data from comparable installations over a 24month period.
Measured on final chip products.
Varies based on rock type and circuit configuration.

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade de rendimento projetada: 250 300 toneladas métricas por hora (275 330 Toneladas dos EUA por hora), depende da dureza do material de alimentação (<200 MPa recomendado) e dimensionamento necessário do produto.
Triturador Primário: Britador de mandíbula modelo JCE1302 / Abertura de alimentação: 1300mm x 900 mm / Tamanho máximo de alimentação: ≤750 mm / Impulsione a potência: 160200 kW.
Triturador Secundário: SingleCylinder or MultiCylinder Cone Crusher / Recommended Power Range: 220315 kW.
Unidades de triagem: Two or three heavyduty vibrating screens with total screening area ≥25 sqm.
Requisito de energia: Total installed plant power approximately 800 1000 kVA.
Principais especificações de materiais: Construção da estrutura principal em aço S355JR; Highstrength conveyor idlers; Revestimentos trituradores de aço manganês; Polyurethane or rubber screen media options.
Pegada Física (Aproximado): Comprimento: ~80m; Largura: ~35m; Altura (máx.): ~15m.
Faixa operacional ambiental: Designed for ambient temperatures from 20°C to +45°C with appropriate options available.

6. CENÁRIOS DE APLICAÇÃO

Granite Quarry Primary Processing Plant

Challenge A granite quarry needed to increase average output to meet new contract demands but faced bottlenecks in secondary crushing due to poor feed gradation from the primary jaw, leading to frequent cone crusher stalls.
Solution Implementation of this optimized threestage plant with an intermediate screen between primary and secondary stages to scalp out fine material before the cone crusher.
Results Throughput stabilized at the target of >280tph consistently; cone crusher utilization improved by over >30%; overall plant availability increased from 90%.

LargeScale Road Base Aggregate Production

Challenge A contractor supplying materials for a major highway project required strict adherence to gradation specifications for multiple road base layers but struggled with segregation on stockpiles due to inconsistent screening efficiency at high volume.
Solution Deployment of the plant featuring multideck final screening towers with sloped chute designs that minimized material drop height onto stockpiles.
Results Product rejection rate due to gradation fell below 290tph when needed.

7 CONSIDERAÇÕES COMERCIAIS

Os níveis de preços de equipamentos são estruturados em torno da configuração principal:
• Nível de configuração básica (~$850k$1M): Includes primary jaw crusher feeder grizzly secondary cone singledeck scalping screen core conveyors basic electrical controls
• Enhanced Configuration Tier (~$1M$1M): Adds tertiary crushing stage multideck final sizing screens automated metal detection dust suppression system
• Turnkey Project Tier (~$M+): Includes full civil works foundation design erection commissioning spares package

Optional features include advanced dust collection systems automated sampling stations remote monitoring telematics packages extended wear part kits

Service packages offered:
• Annual Maintenance Agreement covers scheduled inspections lubrication adjustments parts discount
• OnSite Technician Support packages provide dedicated expert hours per year
• Full Wear Part Lifecycle Contract guarantees costperton over agreed period

Financing options available through partner institutions include equipment leasing longterm rentaltoown agreements project financing solutions

8 Perguntas frequentes

What are the main differences between your plant rated at tph versus one rated at tph?
The tph solution uses heavierduty components throughout including larger diameter shafts higher capacity bearings wider conveyors more robust structural supports This ensures sustainable operation at peak capacity without accelerated wear

How does this plant handle wet or sticky feed material?
We specify lowadhesion liner plates deck heating systems for screens optional washing modules can be integrated into the design These features address buildup that can reduce effective capacity in such conditions

Qual é o cronograma típico de instalação, desde a entrega até o comissionamento?
For prepared site with foundations completed mechanical erection typically requires weeks followed by weeks of electrical commissioning operator training Total project timeline usually falls within months

Are your plants compatible with existing equipment like our current primary loader or downstream systems?
Yes engineering includes interface specifications We design transfer points belt widths speeds control interfaces hopper heights etc ensure seamless integration into your existing operation

What does your aftersales support structure look like?
Support includes detailed operational manuals parts catalogs access regional service technicians comprehensive training program We maintain strategic inventory critical spare parts ensure rapid response times