1. ABERTURA ACIONADA POR PAINPOINT

Are your iron ore processing margins being squeezed by inconsistent feed, excessive downtime, and rising operational costs? Gerentes de fábrica e empreiteiros de engenharia enfrentam desafios persistentes que impactam diretamente os resultados financeiros. Você está experimentando:
Tempo de inatividade não planejado: Freqüente, unpredictable breakdowns in primary crushing due to tramp steel or uncrushable material, halting your entire processing line for hours.
Gargalos de rendimento: Inefficient crushing stages causing backlogs, limiting overall plant capacity and failing to meet offtake agreements during peak demand.
Altos custos de manutenção: Constant wear part replacement in abrasive iron ore applications, coupled with laborintensive servicing routines that drain maintenance budgets.
Variabilidade da qualidade do produto: Inconsistent final product sizing (lump/fines ratio) leading to premium price penalties and customer dissatisfaction.
Ineficiência Energética: Crushing systems operating at nonoptimal levels, consuming excessive power per tonne of ore processed.

What if your primary crushing stage could become a predictable, highavailability asset instead of a recurring cost center?

2. VISÃO GERAL DO PRODUTO

The Bespoke Iron Ore Crushing Plant is a engineered primary and secondary crushing system specifically configured for the highabrasion, hightonnage demands of magnetite or hematite processing. Unlike standard modular plants, each system is designed from the ground up based on your ore characteristics (Abrasion Index, UCS), capacidade necessária, and site logistics.

Fluxo de Trabalho Operacional:
1. Dumping Primário & Pré-triagem: RunofMine (ROM) ore is received at a rugged dump hopper with a grizzly feeder to scalp out oversize material and direct subgrizzly fines to a bypass conveyor.
2. Britagem Primária: A heavyduty jaw crusher or gyratory crusher reduces the ROM ore to a manageable size for downstream conveying.
3. Britagem Secundária & Triagem: Material is conveyed to a secondary cone crusher circuit in closed configuration with sizing screens to ensure precise product control before proceeding to beneficiation.

Escopo de aplicação: Ideal for greenfield sites or major expansion projects requiring 1,500 para 10,000+ capacidade de toneladas por hora. Best suited for operations with consistent longterm mine plans.

Limitações: Not recommended for smallscale or exploratory operations with rapidly changing ore bodies. Site requires adequate preparation for foundation and crane access.

3. RECURSOS PRINCIPAIS

Alimentador de avental para serviço pesado | Base Técnica: Overlapping manganese steel flights driven by rugged tractortype chains | Benefício Operacional: Handles direct dump from 200ton haul trucks without damage, provides even feed regulation to crusher | Impacto do ROI: Eliminates feeder damage downtime; improves crusher cavity fill for up to 15% maior eficiência de rendimento.

Tramp Metal & Cavity Clearance System | Base Técnica: Automated hydraulic release and clearing cylinder on primary crusher | Benefício Operacional: Clears blockages or uncrushable material in minutes without manual intervention | Impacto do ROI: Reduces downtime events from hours to minutes, protecting crusher from catastrophic damage.

Otimização da vida útil do revestimento | Base Técnica: CADdesigned crushing chamber profiles and alloyed manganese steel liners specific to your ore's abrasiveness | Benefício Operacional: Achieves predictable wear life cycles, allowing for planned maintenance shutdowns | Impacto do ROI: Prolonga a vida útil do liner 2035% over generic liners; reduces annual consumable cost per tonne.

Lubrificação Centralizada & Monitoramento de condição | Base Técnica: Automated lubrication system with flow sensors and vibration monitors on critical bearings | Benefício Operacional: Garante a saúde ideal do rolamento, fornece aviso antecipado de possíveis falhas | Impacto do ROI: Prevents major bearing failures; reduces manual greasing labor by estimated 80%.

Modular Conveyor Design | Base Técnica: Bolttogether heavyduty conveyor sections with impact cradles at loading zones | Benefício Operacional: Enables faster installation and future reconfiguration if plant flow needs change | Impacto do ROI: Reduz o tempo de instalação em até 30%, reducing timetoproduction.

Integração de supressão de poeira | Base Técnica: Nozzle system integrated at transfer points, tied into crusher actuation | Benefício Operacional: Significantly reduces airborne particulate from initial crushing stages | Impacto do ROI: Mantém a conformidade regulatória, improves site working conditions and reduces cleanup costs.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Planta Modular) | Bespoke Iron Ore Crushing Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade de planta | 8590% (planejado & não planejado) | 9496% disponibilidade desejada | +510% tempo de atividade mais produtivo |
| Tonne/Hour Efficiency| Rated capacity often at ideal conditions| Capacity guaranteed based on your specific ore AI & densidade| +1015% rendimento consistente |
| Consumo de energia| Fixed speed drives across motors| HVSI crushers & drives de frequência variável (Inversores de frequência) on feeders/conveyors| Até 12% menor kWh/tonelada |
| Custo de desgaste por tonelada| Generic liner designs standard| Orespecific chamber design & liner metallurgy| 2035% redução demonstrada |
| Cronograma de instalação| Sequential assembly on site| Large preassembled skids tested before shipment| 2530% comissionamento mais rápido |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 1,500 TPH acima 10,000 TPH of crushed iron ore.
Opções do britador primário: Maldito Mandíbula (1,600mm x 2.000 mm) ou britador giratório primário (60”+). Selection based on feed size and capacity requirement.
Opções de britador secundário: Highcapacity cone crushers with hydraulic adjustment and clearing.
Requisitos de energia: Total installed power typically ranges from 1.5MW to 6MW+ depending on configuration. Designed for connection to highvoltage mine grid supply (6.6kV/11kV).
Especificações de materiais: Critical wear components utilize premium alloys (por exemplo, TeroTec® manganese steel). Structural steel is Grade S355JR for durability.
Dimensões Físicas: Plant footprint is sitespecific but designed for optimal accessibility around crushers and conveyors for maintenance.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 25°C a +50°C. Dust encapsulation and insulation/heating packages available for extreme climates.

6. CENÁRIOS DE APLICAÇÃO

Greenfield Magnetite Project in Pilbara Region

Desafio: A new mine required a 4,500 TPH primary crushing plant capable of handling highly abrasive ore with minimal water usage due to arid conditions.
Solução: Implementation of a bespoke plant featuring a gyratory primary crusher, dry screening presorting, and fully enclosed conveyors with baghouse filtration.
Resultados: Achieved nameplate capacity within one month of commissioning. Dust emissions maintained below stringent regulatory limits despite dry processing. Wear part life met projected targets within 5%.

Existing Hematite Operation Expansion

Desafio: An existing operation needed to debottleneck its process line; the original primary crusher was causing throughput limitations and excessive maintenance shutdowns.
Solução: A bespoke secondary crushing circuit was designed downstream of the existing primary stage using highperformance cone crushers in closed circuit with multideck screens.
Resultados: Overall plant throughput increased by 22%. Final product sizing consistency improved significantly (+40%), securing premium lump ore pricing from buyers.

7. CONSIDERAÇÕES COMERCIAIS

Our bespoke plants are capital investments engineered for longterm operational payback.

Níveis de preços: Quotations are projectspecific based on detailed client specifications (BOM). Budgetary estimates are provided after initial scoping.
Configuração padrão: Inclui unidades de britagem de núcleo,surge bins,and basic PLC control.Price range indicative only:$8M $15M USD
Configuração avançada: Inclui sistemas de automação,predictive condition monitoring,and advanced dust control.$12M $25M+ USD

Recursos opcionais: Sistemas de pesagem a bordo,estações de amostragem móveis,crusher cavity vision systems,total turnkey erection services.

Pacotes de serviços:

Suporte Platina: Includes remote monitoring,a dedicated service engineer,two scheduled maintenance visits/year,and guaranteed parts delivery within specified timeframe.This package typically adds ~35% CAPEX annually but can reduce unplanned downtime by up to an additional ~50%.

Suporte Ouro: Scheduled maintenance visits/year plus priority parts support.This package typically adds ~23% CAPEX annually

Parts Agreement: Guaranteed wear parts supply at fixed pricepertonne over an agreed period.This stabilizes operating costs

Opções de financiamento: We work with major international equipment finance partners offering leasetoown structures operating leases over typical terms

Perguntas frequentes

Q1 How do you ensure this bespoke plant will work with our existing downstream processing equipment?
A Our engineering process begins with a comprehensive audit of your entire flow sheet including existing conveyors bin capacities We model the entire system using dynamic simulation software ensuring the new crushing plant integrates without creating bottlenecks elsewhere

Q2 What is the typical implementation timeline from order placement?
A For most projects detailed engineering requires months followed by months manufacturing shipping Site preparation must occur concurrently Commissioning typically takes weeks This timeline varies significantly based on scale complexity permitting requirements

Q3 Can you guarantee performance metrics like throughput energy consumption?
A Yes performance guarantees are contractually stipulated following analysis testing They are based on agreedupon standards such as specific Bond Work Index values Abrasion Index values provided during design phase These guarantees form part of our commercial proposal

Q4 How does financing through your partners work?
A Our finance partners provide capital equipment leasing solutions that preserve your working capital Typical agreements involve monthly payments structured as an operating lease often providing potential tax benefits A formal credit application separate from equipment purchase agreement required

Q5 What training do you provide?
A We provide comprehensive training programs covering normal operation routine maintenance troubleshooting safety procedures Training conducted both during Factory Acceptance Testing FAT commissioning period Documentation includes detailed operation manuals parts lists schematic diagrams