1. ABERTURA ACIONADA POR PAINPOINT

Are you managing a midtolarge scale aggregate operation and facing consistent pressure to meet project deadlines while controlling capital and operational expenditure? The challenges of a 250300tph stone crushing plant are significant. Inconsistent feed material causes unexpected wear and downtime on critical components. Bottlenecks in one crushing stage throttle the entire line’s output, leaving capacity unrealized. Rising energy costs directly erode profit margins on every ton produced. Além disso, frequent maintenance interrupts production schedules, and configuring a plant for multiple product specifications often requires manual adjustments and costly delays.

How do you achieve reliable 300tonperhour output without excessive maintenance overhead? Can your plant adapt to varying feed hardness and size without sacrificing final product gradation? Is your current solution delivering the expected return on investment through sustained availability and low costperton?

2. VISÃO GERAL DO PRODUTO

Este produto é completo, stationary 250300tph turnkey stone crushing and screening plant designed for highvolume production of aggregates for road base, concreto, e asfalto. It is engineered for primary contractors and quarry operators requiring consistent, specificationgrade output.

Fluxo de Trabalho Operacional:
1. Britagem Primária: Alimentação grande (≤750 mm) é reduzido por um britador de mandíbula robusto ou impactor primário.
2. Secundário & Britagem Terciária: Material is conveyed to cone crushers or secondary impactors for further size reduction and shaping.
3. Triagem: Multipledeck vibrating screens precisely separate crushed material into required product sizes (por exemplo, 05milímetros, 510milímetros, 1020milímetros).
4. Manuseio de Materiais: A network of conveyors with centralized control transfers material between stages and to final stockpiles.
5. Supressão de poeira: Sistemas de pulverização integrados nos pontos de transferência controlam as emissões de partículas, ensuring environmental compliance.

Escopo de aplicação & Limitações:
Escopo: Ideal para hard rock (granito, basalto), calcário, and river gravel applications. Suited for permanent installation in large quarry sites or major infrastructure project batching plants.
Limitações: Não concebido como equipamento móvel ou semimóvel. Feed size and material abrasiveness must align with configured crusher chamber selections for optimal performance.

3. RECURSOS PRINCIPAIS

Design modular de deslizamento | Base Técnica: Pré-montado, steelframed substructures | Benefício Operacional: Reduz o tempo de instalação no local em até 40%, ensures precise factory alignment of motors and drives | Impacto do ROI: O comissionamento mais rápido acelera a geração de receita; standardized modules simplify future maintenance.

Sistema Inteligente de Controle de Processo | Base Técnica: Automação baseada em PLC com algoritmos de compartilhamento de carga | Benefício Operacional: Optimizes crusher feed rates in realtime to prevent choking or running empty; monitors power draw for peak efficiency | Impacto do ROI: Reduces energy consumption per ton by an estimated 815% and minimizes operator error.

HeavyDuty Wear Component Package | Base Técnica: Barras de sopro de alto cromo, manganese steel jaws/concaves, reinforced screen meshes | Benefício Operacional: Prolonga os intervalos de manutenção 3050% in abrasive applications, maintains consistent product gradation longer | Impacto do ROI: Lowers costperton for wear parts and reduces downtime frequency for component changeouts.

MultiStage Dust Control Integration | Base Técnica: Strategically placed spray nozzles with solenoid valves tied to conveyor operation | Benefício Operacional: Effectively suppresses dust at each transfer point, improving site visibility and operator health | Impacto do ROI: Mitigates risk of environmental noncompliance fines and reduces cleanup labor.

Lubrificação Centralizada & Sistema de Lubrificação | Base Técnica: Automated pump system with distribution lines to key bearing points | Benefício Operacional: Ensures critical bearings receive correct lubrication on schedule without manual intervention | Impacto do ROI: Evita falha prematura do rolamento, a leading cause of unplanned downtime.

HighCapacity Vibrating Screens with Deck Access System | Base Técnica: Large screening area with adjustable throw; integrated walkways & plataformas | Benefício Operacional: Maximizes screening efficiency; fornece segurança, easy access for mesh inspection and replacement | Impacto do ROI: Improves final product quality control and enhances worker safety during routine checks.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (250300planta tph) | This 250300tph Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade de planta | 8588% (incluindo manutenção planejada) | 92%+ (engineered design) | +47% tempo de atividade |
| Consumo de energia (kWh/tonelada)| Varia muito; often not optimized per stage| Managed via intelligent load control| Até 15% reduction demonstrable |
| Wear Life on Abrasive Rock| Standard manganese/chrome components| Premium alloy selection & otimização de câmara| +30% aumento médio |
| Instalação & Tempo de comissionamento| 812 weeks onsite assembly| ~57 weeks (modular skid design)| ~40% reduction |
| Consistência de gradação de produto| Manual feed adjustment leads to variance| Automated setting regulation (ASRitype systems)| Variance improved by up to 25% |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade de rendimento projetada: 250 300 toneladas métricas por hora (varies based on feed material hardness & distribuição de tamanho).
Opções do britador primário: Maldito Mandíbula (900x1200mm) ou britador de impacto primário (Φ1600x2000mm).
Triturador Secundário/Terciário: Two units of Hydraulic Cone Crushers (por exemplo, HPC315).
Screening Stations: Two units of TripleDeck HeavyDuty Vibrating Screens (2400x6000mm).
Potência Total Instalada: Aproximadamente 800 950 kW.
Principais especificações de materiais: Main frame structure fabricated from Q345B steel; wear liners use Mn18Cr2 or equivalent highgrade alloys.
Pegada geral da planta (C x L): ~120m x 85m (layout can be customized).
Faixa operacional ambiental: Projetado para temperatura ambiente de 20°C a +45°C; dust emission control meets standard regulatory limits (<20mg/m³ at property boundary).

6. CENÁRIOS DE APLICAÇÃO

Highway Construction Base Course Production | Desafio: A national infrastructure project required consistent supply of three graded aggregates for road base layers from highly abrasive granite. The existing plant struggled with rapid wear and inconsistent sizing, threatening project timelines.| Solução: Implementation of this heavyduty configured plant featuring cone crushers with automated settings control and premium wear packages.| Resultados: Achieved sustained output of 280tph. Wear part life increased by over 35%, reducing changeout downtime. Product gradation consistency met strict highway authority specifications throughout the contract.

Commercial Limestone Quarry Expansion | Desafio: A quarry expanding its market needed to increase finished product range without adding separate processing lines or excessive manual sorting.| Solução: Installation of this multistage plant with precise secondary/tertiary crushing circuits and highefficiency multideck screens.| Resultados:The plant reliably produces five distinct products simultaneously—from coarse aggregate to manufactured sand—at a combined rate exceeding 270tph, enabling entry into new concrete and asphalt mix markets.

7. CONSIDERAÇÕES COMERCIAIS

Our approach provides clarity in investment planning:

Níveis de preços: We offer three standard configurations:
Essencial: Core crushing & screening modules for reliable singleproduct output.
Avançado: Includes automation systems, enhanced dust control, wider conveyor specification.
Prêmio: Full turnkey package with premium wear materials package extended warranty coverage

Recursos opcionais & Atualizações: Specific options include automated metal detection/rejection systems advanced rockonrock shaping chambers additional sound attenuation enclosures remote monitoring telematics packages

Pacotes de serviços: Choose from annual maintenance contracts providing scheduled inspections guaranteed spare parts delivery priority technical support Extended warranty plans are available covering major structural components

Opções de financiamento: We work with established financial partners offer flexible leasing arrangements milestonebased project financing solutions tailored capital expenditure plans

8.Perguntas frequentes

1.P:What if our feed rock hardness exceeds the standard design parameters?
UM:The plant's core structural design accommodates high loads but we conduct a detailed feed material analysis during quotation For extremely hard or abrasive materials we specify upgraded wear component alloys chamber geometries ensure designed throughput longevity

2.Q How does this plant manage fluctuations in incoming feed size?
A The intelligent process control system regulates feeder speeds based realtime crusher motor load preventing choking This combined surge pile capacity before primary crusher smooths out typical frontend loader variation

3.Q What typical timeframe expected from order placement commissioning?
A For standard configuration lead time manufacturing shipping approximately months Onsite installation commissioning modular skid design typically requires weeks depending local civil works readiness

4.Q Are spare parts readily available longterm?
A Yes We maintain global inventory strategic wear parts provide guaranteed stockholding agreements as part service packages All major mechanical electrical components internationally standardized brands ensuring supply chain redundancy

5.Q Can existing equipment integrated into new plant?
A Potentially yes An initial audit your current conveyors screens can determine compatibility integration feasibility often possible especially material handling equipment reducing overall project cost

6.Q What ongoing operational staffing requirements?
A The automated central control system allows efficient operation primary operators monitoring stations Additional personnel required routine mechanical checks stockpile management but labor intensity significantly lower versus manually controlled plants

7.Q What key factors influence final price quotation?
A Final pricing determined specific equipment selection required options degree site preparation needed local regulatory compliance costs shipping logistics destination Comprehensive site survey forms basis fixedprice turnkey proposal