1. ABERTURA ACIONADA POR PAINPOINT

Você está gerenciando uma operação de produção agregada de médio a grande porte e enfrentando gargalos persistentes que prejudicam a lucratividade?? Para gerentes de fábrica e empreiteiros de engenharia, uma planta de britagem de pedra de 250.300 tph é um ativo de capital crítico, no entanto, seu desempenho determina diretamente seus resultados financeiros. Common operational challenges include:
Taxa de transferência inconsistente: Fluctuations in feed material hardness or size leading to an average output below the 280tph design target, causing project delays and missed delivery schedules.
Tempo de inatividade excessivo: Frequent mechanical failures in key components or lengthy changeover times for maintenance, resulting in hundreds of lost production hours annually.
Altos custos operacionais: Uncontrolled wear part consumption, inefficient power draw per ton of processed material, and the labor intensity of routine monitoring.
Variabilidade da qualidade do produto: Inability to consistently meet multiple spec products (por exemplo, 05milímetros, 1020milímetros, 2040milímetros) simultaneously due to inflexible or poorly calibrated crushing stages.
Limitações de escalabilidade: A fixed plant configuration that cannot adapt to changing project demands or feed materials without significant capital reinvestment.

A questão central é: how do you select a 250300tph crushing plant that transforms these cost centers into reliable, predictable production?

2. VISÃO GERAL DO PRODUTO

Este produto é completo, estacionário 250300 TPH Hard Stone Crushing and Screening Plant. It is engineered for continuous, highvolume production of aggregates for large infrastructure projects, commercial concrete batching, and road base construction.

Fluxo de Trabalho Operacional:
1. Britagem Primária: Material de alimentação grande (≤750 mm) é reduzido para ≤200 mm por um britador de mandíbula primário robusto.
2. Secundário & Britagem Terciária: Material is conveyed to a cone crusher circuit for further reduction, producing precisely shaped intermediates.
3. Triagem & Classificação: Multipledeck vibrating screens separate crushed material into specified finished product sizes.
4. Recirculação: Oversize material is automatically returned via conveyors to the appropriate crusher for reprocessing (projeto de circuito fechado).
5. Estoque: Finished aggregates are conveyed to designated stockpiles for loadout.

Escopo de aplicação & Limitações:
Escopo: Ideal para processamento de granito, basalto, seixos do rio, and other abrasive materials with compressive strength up to 350MPa. Suited for permanent quarry sites or longduration (3+ ano) project bases.
Limitações: Not designed as mobile or semimobile equipment; relocation requires disassembly. Maximum feed size and final capacity are contingent on specific material characteristics. Not optimal for processing sticky or highclay content materials without prescreening/scalping modifications.

3. RECURSOS PRINCIPAIS

Triturador Primário Pesado | Base Técnica: Cinemática otimizada & highstrength steel castings | Benefício Operacional: Sustained throughput with abrasive feeds, reduced risk of premature fatigue failure | Impacto do ROI: Lower costperton in primary stage by extending service intervals ≥25%

Automação inteligente da câmara de britagem | Base Técnica: Hydroset CSS adjustment & realtime pressure monitoring | Benefício Operacional: Remote adjustment of product size and automatic overload protection without stopping production | Impacto do ROI: Minimizes unplanned stoppages and allows quick adaptation to different product specs

MultiStage Screening with Recirculation | Base Técnica: High Gforce vibrating screens with modular deck options | Benefício Operacional: Precise classification into up to 4 final products simultaneously; maximizes plant efficiency by reducing crusher load | Impacto do ROI: Increases saleable product yield by ensuring spec compliance

Sistema de controle PLC centralizado | Base Técnica: Controlador lógico programável com interface homem-máquina (IHM) panel | Benefício Operacional: Singlepoint monitoring/control of entire flow, fault diagnostics, and production data logging | Impacto do ROI: Reduces operational labor requirements and enables datadriven maintenance planning

Sistema integrado de supressão de poeira | Base Técnica: Conjuntos de bicos em pontos de transferência conectados ao abastecimento de água & pump | Benefício Operacional: Actively controls airborne particulate at primary sources | Impacto do ROI: Mitigates environmental compliance risks and reduces wear on machinery from dust ingress

Modular Structural Design | Base Técnica: Prefabricated bolttogether support structures and walkways | Benefício Operacional: Streamlined installation and future potential for plant reconfiguration or expansion | Impacto do ROI: Lowers initial installation time/cost by approximately 1520%

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Industry Standard for 250300tph Plant | Our 250300tph Stone Crushing Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Tempo de atividade)| ~85% 88% (planejado & tempo de inatividade não planejado) |> 92% (contractually backed) |> +5% para +8% |
| Consumo de energia| Média 0.8 1.0 kWh per ton of output |> ≤ 0.75 kWh por tonelada |> Até 15% Redução |
| Wear Part Cost/Ton| Varia muito; often a reactive expense |> Guaranteed maximum cost/ton in service contract |> Predictable cost model; poupança típica de 1020% |
| Índice de formato do produto| ≥ 95% conteúdo cúbico |> Improved concrete mix quality & asphalt binding |
| Instalação & Tempo de comissionamento| 8 12 semanas |> Target of 6 8 semanas |> Até 25% Faster TimetoProduction |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade Projetada: 250 300 toneladas métricas por hora (varies based on feed material and product size).
Triturador Primário: Jaw Crusher Model [por exemplo, JC1303], Feed Opening ≥1000x800mm.
Secondary/Tertiary Crusher: Hydraulic Cone Crusher Model [por exemplo, HPC315], with automatic control system.
Telas: Two units of TripleDeck Inclined Vibrating Screens (Size e.g., 2400x6000mm).
Requisito de energia: Total installed power ~450 500 kW; mains voltage as per client specification.
Principais especificações de materiais: Main frame fabricated from Q345B steel; crusher liners from Mn18Cr2 alloy; conveyor belts rated for heavy impact (EP400/3).
Overall Plant Footprint (CxL): Approximately ~80m x ~45m (layout dependent).
Faixa operacional ambiental: Designed for ambient temperatures from 20°C to +45°C with appropriate options for dust control and noise attenuation.

6. CENÁRIOS DE APLICAÇÃO

Highway Construction Project – Southeast Asia

Challenge A contractor needed consistent supply of three aggregate specifications (05mm sand substitute,1020milímetros &2031.5mm chip) from highly abrasive granite to meet tight paving deadlines.Downtime was not an option.
Solution Implementation of a tailored270 tph hard stone crushing plant featuring an extraheavyduty primary jaw crusher,a multichamber cone crusher setup,and aggressive screening decks.
Results The plant achieved an average output of285 tph over18 months.Product shape met EN standard requirements,and the plant’s availability rate was recorded at93%.The project finished ahead of schedule due toreliable onsite aggregate supply.

Commercial Granite Quarry – Eastern Europe

Challenge An existing quarry operation’s aging singlestage plant produced excessive flaky product unsuitedfor highvalue concrete applications,capping revenue potential.The system also suffered from high energy costs per ton.
Solution Replacement with a new300 tph threestage crushing and screening plant focused on cubicity.The design included advanced chamber optimization technology in the cone crushersand highefficiency motors across all drives.
Results Field data shows cubical content improved from~85%to96%.Energy consumption dropped by18%,and the abilityto produce premiumpriced aggregates increased overall quarry profitability byan estimated22%.

LargeScale Dam Project – South America

Challenge Processing massive volumesof river basaltwith fluctuating moisture content.Previous setups experienced frequent cloggingat screening stagesand conveyor transfer points,causing daily operational delays.
Solution A robust250 tphplant was configuredwith reinforced grizzly prescreening,a nonclog designed secondary impactor optionfor sticky material,and covered conveyorswith targeted cleanout points.The dust suppression system wasspecifically calibratedfor variable moisture conditions.
Results Throughput stabilized at design capacity.Plant clogging incidents were reducedby over90%,and the enclosed conveying minimized material lossand spillage,savingan estimated50 tonsper weekin recoveredproduct.

Considerações Comerciais

Pricingfora complete250–300tph stone crushingplantis projectspecific,but falls withina capital investment tier typically rangingfrom$1.2millionto$2.5millionUSD,finalized upon configuration.

Recursos opcionais:
Automated Wear Monitoring Systems
Onboard Power Generation Package
Advanced Noise Enclosure Modules
Remote Telematics & Performance Reporting Portal
Spare Parts Starter Kit

Pacotes de serviços:
1.Garantia Básica:Covers parts&labor formajor componentsfor12 months/2，000 horas。
2.Planned Maintenance Package:Scheduled inspections，substituição de peças de desgaste，and annual overhauls fora fixed annual fee。
3.Contrato de serviço completo(Recomendado):Guarantees uptime(≥92%)，covers all parts(excluding consumables)，trabalho，and includes priority technical support。This converts unpredictable repair costsintoa fixed operational expense。

Opções de financiamento:
We workwith international financial partners toofferflexible solutions including equipment leasing，longterm installment plans(36–60 months)，or projectlinked financing。A preliminary feasibility study can be preparedtosupport your investment case。

Perguntas frequentes

Q Whatis themaximum input sizeyourplantcan accept?
A Theprimary jawcrusherconfigurationacceptsfeedmaterialupto750mmin size。For optimal performance andreduced wear，we recommendprescreeningor grizzly feedingto remove sub–200mmfinesbeforetheprimary stage。

Q How many personnelare requiredto operatetheplant?
A ThecentralizedPLCcontrolsystemallowsforefficientoperationbya crewof2–3personnelformonitoring，carregando，and basic quality checks。Maintenanceis handledbyaseparatecrew。

Q Areyourplants compatiblewithexistingequipmentlikefeedersorscreenersfromother manufacturers?
Sim。Ourplantsaredesignedformodular integration。We can interfacewithyour existingfeed systems，transportadores，or ancillary equipmentprovidedtechnical specificationsare sharedduringtheengineering phase。

Q Whatisthetypical deliveryandlead timefromorderto commissioning?
A Forastandardconfiguration，lead timeis approximately16–20weeksexworks。Deliveryand installation timelinesdependonsite readinessand location；ourproject management teamprovidesadetailed schedule。

Q Doyouprovideperformance guarantees?
Sim。We providecontractual guaranteeson rated capacity(basedon agreed feed material)，final product gradation，and total power consumption。Theseareverifiedduringthecommissioningacceptance tests。

Q Whatistheexpectedlifespanofthemain structuralcomponents?
A Themain structuralsteelframeworkis designedfora minimumservice lifeof20+yearsunder normal operating conditionswhen maintainedasper guidelines。

Q Canthisplantbeupgradedtoahighercapacityinthefuture?
A Themajormodular designallowsforscalability。Common upgradesinclude replacingcrushers withhighercapacity modelsor addingsupplementary screening units；this can befactoredintotheinitial layoutplanning