1. ABERTURA ACIONADA POR PAINPOINT

Are you managing a midtolarge scale aggregate production operation and facing consistent bottlenecks in output and predictability? Sourcing a 250300tph stone crushing plant is a major capital decision, yet the true cost extends far beyond the initial equipment invoice. Os desafios comuns incluem:

Unpredictable Throughput: Inconsistent feed material or poorly matched crusher stages can cause your plant to operate below its rated 300tph capacity, impactando diretamente os cronogramas e receitas do projeto.
Tempo de inatividade operacional excessivo: Frequent maintenance stops for liner changes, clogging, or component failure erode your operational window. Industry data indicates that unplanned downtime can cost over $10,000 per hour in lost production for a plant of this scale.
Hidden Sourcing and Commissioning Costs: Engaging a sourcing agent without clear technical specifications can lead to misaligned equipment, costly shipping errors, and prolonged onsite assembly, delaying your ROI.
High LongTerm Operating Costs: Inefficient power draw from poorly configured motors and conveyors, combined with rapid wear part consumption in abrasive environments, significantly increases your cost per ton.

A questão central é: how do you specify a plant that delivers reliable 250300tph throughput while controlling the total cost of ownership from sourcing through to daily operation?

2. VISÃO GERAL DO PRODUTO

A 250300tph stationary stone crushing plant is a complete material processing system designed for highvolume production of aggregates for construction, base rodoviária, e lastro ferroviário. Ele transforma grandes (até 750 mm) quarryrun rock into precisely sized fractions (por exemplo, 05milímetros, 520milímetros, 2040milímetros).

Fluxo de Trabalho Operacional:
1. Britagem Primária: Dump trucks feed material into a primary jaw crusher for initial size reduction.
2. Secundário & Britagem Terciária: A saída é transmitida para o secundário (por exemplo, triturador de cone) and possibly tertiary crushers for further refinement to desired cubicity.
3. Triagem & Classificando: Vibrating screens separate crushed material into specified size fractions.
4. Manuseio de Materiais: A network of conveyors transfers material between stages and to final stockpiles.
5. Supressão de poeira: Integrated spray systems control particulate emissions at transfer points.

Escopo de aplicação & Limitações:
This plant is engineered for hard rock (granito, basalto) and abrasive materials in fixedlocation quarries. It requires stable foundation preparation and consistent electrical power supply (typically 400V/50Hz or 480V/60Hz). It is not suitable for highly mobile operations or processing very soft, materiais argilosos sem pré-processamento significativo.

3. RECURSOS PRINCIPAIS

Projeto de planta modular | Base Técnica: Pré-projetado, skidmounted modules | Benefício Operacional: Reduces onsite civil work and commissioning time by up to 40% compared to traditional foundations | Impacto do ROI: Faster operational startup accelerates revenue generation

Geometria Inteligente da Câmara de Britagem | Base Técnica: Optimized nip angles and cavity profiles in jaw and cone crushers | Benefício Operacional: Increases crushing efficiency for a given power input, reducing energy consumption per ton by approximately 15% | Impacto do ROI: Direct reduction in monthly power costs

Sistema de controle PLC centralizado | Base Técnica: Controlador lógico programável com interface homem-máquina (IHM) | Benefício Operacional: Enables singleoperator monitoring of the entire flow, provides realtime diagnostics, and allows for quick adjustment of crusher settings | Impacto do ROI: Lowers labor requirements and minimizes faultfinding time during stoppages

HeavyDuty Vibrating Screens with Polyurethane Decks | Base Técnica: High Gforce screening action with abrasionresistant deck surfaces | Benefício Operacional: Provides consistent sizing accuracy and extends deck life by over 30% compared to standard wire mesh | Impacto do ROI: Reduces screen media replacement frequency and inventory costs

Sistema integrado de supressão de poeira | Base Técnica: Nozzle arrays at all major transfer points with solenoid valve control | Benefício Operacional: Maintains compliance with site environmental regulations without excessive water usage | Impacto do ROI: Avoids potential fines and work stoppages due to environmental noncompliance

Universal Conveyor Belt Design | Base Técnica: Standardized belt width, idler spacing, and motor ratings across the plant | Benefício Operacional: Simplifies maintenance procedures and reduces spare parts inventory complexity | Impacto do ROI: Lowers longterm maintenance training costs and parts holding capital

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da indústria para plantas de 250.300 tph | Nossa solução de planta de britagem de pedra de 250.300 tph | Vantagem (% Melhoria) |
| : | : | : | : |
| Consumo de energia | ~450 kWh per operating hour average (site dependent) ~375 kWh per operating hour average (site dependent) ~375 kWh per operating hour average (site dependent)| Optimized drive systems & highefficiency motors reduce draw ~375 kWh per operating hour average (site dependent)| Up to ~17% reduction in energy use |
| Cone Crusher Liner Life| Manganese steel liners lasting ~12001500 hours in abrasive granite| Proprietary alloy liners & chamber design extend service life| +25% increase in operational hours between changes |
| Disponibilidade de planta| Alvo de 90% (aprox.. 7884 hrs/year)| Robust design & accessible service points increase runtime| Conquistas >92% disponibilidade (+2% absolute improvement) |
| Tempo de comissionamento no local| Tipicamente 46 semanas após a entrega do componente| Preassembled modules & plugandplay wiring reduce labor| Commissioning completed within <3 semanas (33%) |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade de rendimento projetada: Adjustable range of 250 300 toneladas métricas por hora (based on feed material density ~1.6 t/m³).
Triturador Primário: Jaw Crusher Model JCE1302; Tamanho da abertura de alimentação:1300x1000 mm; Max Feed Size750 mm; Power315 kW.
Triturador Secundário/Terciário: Hydraulic Cone Crusher Model HCC1680; Closed Side Setting Range2050 mm; Power315 kW.
Estágio de Triagem: Two units of Triple Deck Vibrating Screen Model VSI2460; Screening Area14.4 m² per deck; Power22 kW each.
Manuseio de Materiais: Main Conveyor Belt Width1200 mm; Belt Speed1.6 m/s; Total Installed Conveyor Length~150 meters.
Electrical System Requirements: Total Connected Power~850 kW; Main Voltage Supply400V/50Hz or480V/60Hz; Requires dedicated transformer substation.
Principais especificações de materiais: Primary crusher frame fabricated from Q345B steel; Conveyor idlers feature C5 bearing class with >50khour L10 life expectancy.
Faixa operacional ambiental: Designed for ambient temperatures from 20°C to +45°C with appropriate lubrication specifications.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Challenge A quarry operator needed to increase annual output by over million tons but faced space constraints limiting plant footprint expansion required new highcapacity circuit within existing boundaries Solution Implementation of our compact modular tph crushing plant featuring three stage crushing closed circuit design Results Plant installed on prepared pad within weeks achieving steady state throughput of tph produced aggregate meeting all cubicity specifications for premium concrete applications

Railway Ballast Production

Challenge Contractor securing major rail link project required guaranteed supply of high specification ballast material demanding precise particle shape distribution minimal fines content Solution Deployment of tph plant configured with primary jaw secondary cone tertiary cone crushers in series alongside aggressive screening setup Results System consistently delivered tph of ballast achieving particle index values below as per project specification enabling contractor to maintain tight construction schedule

Urban Construction Aggregate Supply

Challenge Aggregate supplier near metropolitan area needed high volume plant with stringent dust emission controls noise mitigation due proximity residential zones Solution Our tph solution equipped advanced enclosed dust suppression system sound dampening panels on key equipment like screens conveyors Results Plant passed all municipal environmental audits operates within permissible decibel limits maintaining social license operate while meeting daily demand metro construction projects

CONSIDERAÇÕES COMERCIAIS

Equipment pricing tiers structured around core configuration options Standard Plant Package includes primary secondary crushing basic screening starts Tier Upgrades include tertiary crusher module automated metal detection system advanced dust control package Service packages available ranging from basic warranty extended year comprehensive coverage including scheduled maintenance inspections wear part discounts Financing options offered through partner institutions include capital lease operating lease structures typical terms years facilitate cash flow management Optional features remote monitoring telematics system automated lubrication systems further reduce operational labor requirements

Perguntas frequentes

What type electrical infrastructure required operate this plant The system requires stable three phase supply voltage either typically supported dedicated kVA transformer substation site survey recommended confirm compatibility How quickly can wear parts like crusher liners replaced Field data shows full liner change secondary cone crusher performed hours using standard tools minimizing downtime Is this plant suitable processing river gravel Yes but configuration may require additional washing scrubbing equipment remove silt clay which handled optional module Can output gradation adjusted easily Yes final product sizes adjusted changing screen deck meshes adjusting closed side settings cone crushers via hydraulic system takes minutes operator What included standard commissioning package Our commissioning includes supervision assembly mechanical electrical checks performance test run training your operators safe efficient plant management typical duration weeks Are financing payments eligible capitalization Yes most financing structures allow payments capitalized asset improving balance sheet presentation versus direct expense